Novel ester compounds, polymers, resist compositions and patterning process

ABSTRACT

Novel ester compounds having formula (1) wherein A 1  is a polymerizable functional group having a double bond, A 2  is furandiyl, tetrahydrofurandiyl or oxanorbornanediyl, R 1  and R 2  each are a monovalent hydrocarbon group, or R 1  and R 2  may bond together to form an aliphatic hydrocarbon ring with the carbon atom, and R 3  is hydrogen or a monovalent hydrocarbon group which may contain a hetero atom are polymerizable into polymers. Resist compositions comprising the polymers are sensitive to high-energy radiation, have an improved sensitivity, resolution, and etching resistance, and lend themselves to micropatterning with electron beams or deep-UV rays.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a 37 C.F.R. § 1.53(b) divisional of U.S. application Ser. No. 10/671,948 filed Sep. 29, 2003, which in turn claims priority on Japanese Application No. 2002-285161 filed Sep. 30, 2002. The entire contents of each of these applications is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to (1) a novel ester compound, (2) a polymer comprising units of the ester compound which is blended as a base resin to formulate a chemically amplified resist composition suitable in the micropatterning technology, (3) a resist composition comprising the polymer, and (4) a patterning process using the resist composition.

2. Prior Art

While a number of recent efforts are being made to achieve a finer pattern rule in the drive for higher integration and operating speeds in LSI devices, deep-ultraviolet lithography is thought to hold particular promise as the next generation in microfabrication technology. In particular, photolithography using a KrF or ArF excimer laser as the light source is strongly desired to reach the practical level as the micropatterning technique capable of achieving a feature size of 0.3 μm or less.

For resist materials for use with a KrF excimer lasers, polyhydroxystyrene having a practical level of transmittance and etching resistance is, in fact, a standard base resin. For resist materials for use with ArF excimer lasers, polyacrylic or polymethacrylic acid derivatives and polymers comprising cycloaliphatic compounds in the backbone are under investigation. In either case, the basic concept is that some or all of alkali soluble sites of alkali soluble resin are protected with acid labile or eliminatable groups. The overall performance of resist material is adjusted by a choice from among a variety of acid eliminatable protective groups.

Exemplary acid eliminatable protective groups include tert-butoxycarbonyl (JP-B 2-27660), tert-butyl (JP-A 62-115440 and J. Photopolym. Sci. Technol. 7 [3], 507 (1994)), 2-tetrahydropyranyl (JP-A 2-80515 and JP-A 5-88367), and 1-ethoxyethyl (JP-A 2-19847 and JP-A 4-215661). While it is desired to achieve a finer pattern rule, none of these acid eliminatable protective groups are deemed to exert satisfactory performance.

More particularly, tert-butoxycarbonyl and tert-butyl are extremely less reactive with acids so that a substantial quantity of energy radiation must be irradiated to generate a sufficient amount of acid in order to establish a difference in rate of dissolution before and after exposure. If a photoacid generator of the strong acid type is used, the exposure can be reduced to a relatively low level because reaction can proceed with a small amount of acid generated. However, in this event, the deactivation of the generated acid by air-borne basic substances has a relatively large influence, giving rise to such problems as a T-top pattern. On the other hand, 2-tetrahydropyranyl and 1-ethoxyethyl are so reactive with acids that with the acid generated by exposure, elimination reaction may randomly proceed without a need for heat treatment, with the result that substantial dimensional changes occur between exposure and heat treatment/ development. Where these groups are used as protective groups for carboxylic acid, they have a low inhibiting effect to alkali dissolution, resulting in a high rate of dissolution in unexposed areas and film thinning during development. If highly substituted polymers are used to avoid such inconvenience, there results an extreme drop of heat resistance. These resins fail to provide a difference in rate of dissolution before and after exposure, resulting in resist materials having a very low resolution.

For the above-described resist materials using acid-eliminatable protective groups, there is a common problem of line density dependency that when a pattern to be transferred includes dense and sparse regions, it is impossible to produce the desired pattern in both the dense and sparse regions at the same exposure. More particularly, with respect to the formation of a line-and-space pattern, for example, if solitary lines are formed at an exposure that can resolve crowded lines with good size control, they are finished to a line width less than the desired size. Presumably this phenomenon is ascribable to the increased diffusion length of acid generated upon exposure. There is a tendency that the diffusion of the generated acid is enhanced as the system becomes more hydrophobic. Since both (meth)acrylic resins and cycloaliphatic backbone resins have increased their carbon density in order to improve etching resistance, the diffusion of the generated acid is more promoted as a result, exaggerating line density dependency. Then at the very fine pattern size for which an ArF excimer laser is actually used, a resist material having substantial line density dependency cannot be used in an industrially acceptable manner because solitary lines can disappear. While a finer pattern rule is being demanded, there is a need to have a resist material which is not only satisfactory in sensitivity, resolution, and etching resistance, but also minimized in line density dependency.

SUMMARY OF THE INVENTION

Therefore, an object of the present invention is to provide (1) a novel ester compound capable of forming a polymer which is effectively acid-decomposable and can control the diffusion of the acid generated upon exposure, (2) a polymer which is blended as a base resin to formulate a resist composition having a higher sensitivity and resolution than conventional resist compositions as well as minimized line density dependency, (3) a resist composition comprising the polymer as a base resin, and (4) a patterning process using the resist composition.

It has been found that ester compounds of the general formula (1), shown below, can be prepared in high yields by a simple method to be described later; that polymers obtained using the ester compounds have high transparency at the exposure wavelength of an excimer laser; that resist compositions comprising the polymers as the base resin have a high sensitivity, high resolution and minimized line density dependency; and that these resist compositions lend themselves to precise micropatterning.

In a first aspect, the invention provides an ester compound having the general formula (1).

Herein A¹ is a polymerizable functional group having a carbon-to-carbon double bond, A² is a divalent group selected from among furandiyl, tetrahydrofurandiyl and oxanorbornanediyl, R¹ and R² are each independently a straight, branched or cyclic monovalent hydrocarbon group having 1 to 10 carbon atoms, or R¹ and R² may bond together to form an aliphatic hydrocarbon ring with the carbon atom to which they are bonded, and R³ is hydrogen or a straight, branched or cyclic monovalent hydrocarbon group having 1 to 10 carbon atoms which may contain a hetero atom.

In a preferred embodiment, the ester compound has the general formula (2).

Herein R¹ and R² are as defined above, and R⁴ is hydrogen or methyl.

In another preferred embodiment, the ester compound has the general formula (3).

Herein R¹, R² and R⁴ are as defined above, and k¹ is 0 or 1.

In a second aspect, the invention provides a polymer comprising recurring units derived from the ester compound.

Another embodiment is a polymer comprising recurring units of any one of the general formulae (1a) to (1c).

Herein A¹ is a polymerizable functional group having a carbon-to-carbon double bond, A² is a divalent group selected from among furandiyl, tetrahydrofurandiyl and oxanorbornanediyl, R¹ and R² are each independently a straight, branched or cyclic monovalent hydrocarbon group having 1 to 10 carbon atoms, or R¹ and R² may bond together to form an aliphatic hydrocarbon ring with the carbon atom to which they are bonded, R³ is hydrogen or a straight, branched or cyclic monovalent hydrocarbon group having 1 to 10 carbon atoms which may contain a hetero atom, R⁴ is hydrogen or methyl, and k¹ is 0 or 1.

The polymer may further comprise recurring units of any one of the general formulae (M1) to (M13).

Herein R⁰⁰¹ is hydrogen, methyl or CH₂CO₂R⁰⁰³; R⁰⁰² is hydrogen, methyl or CO₂R⁰⁰³; R⁰⁰³ is a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms; R⁰⁰⁴ is hydrogen or a monovalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group; at least one of R⁰⁰⁵ to R⁰⁰⁸ represents a monovalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group while the remaining R's independently represent hydrogen or a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms, or R⁰⁰⁵ to R⁰⁰⁸, taken together, may form a ring, and in that event, at least one of R⁰⁰⁵ to R⁰⁰⁸ is a divalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group, while the remaining R's are independently single bonds or straight, branched or cyclic alkylene groups of 1 to 15 carbon atoms; R⁰⁰⁹ is a monovalent hydrocarbon group of 2 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide; at least one of R⁰¹⁰ to R⁰¹³ is a monovalent hydrocarbon group of 2 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide, while the remaining R's are independently hydrogen or straight, branched or cyclic alkyl groups of 1 to 15 carbon atoms, or R⁰¹⁰ to R⁰¹³, taken together, may form a ring, and in that event, at least one of R⁰¹⁰ to R⁰¹³ is a divalent hydrocarbon group of 1 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide, while the remaining R's are independently single bonds or straight, branched or cyclic alkylene groups of 1 to 15 carbon atoms; R⁰¹⁴ is a polycyclic hydrocarbon group having 7 to 15 carbon atoms or an alkyl group containing a polycyclic hydrocarbon group; R⁰¹⁵ is an acid labile group; X is CH₂ or an oxygen atom or sulfur atom; Y′ is —O— or —(NR^(f))—; R^(f) is hydrogen atom or a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms; and k is 0 or 1.

In a third aspect, the invention provides a resist composition comprising the polymer defined above.

In a fourth aspect, the invention provides a process for forming a resist pattern comprising the steps of applying the resist composition onto a substrate to form a coating; heat treating the coating and then exposing it to high-energy radiation or electron beams through a photomask; and optionally heat treating the exposed coating and developing it with a developer.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Ester

The ester compounds of the invention have the general formula (1).

In formula (1), A¹ is a polymerizable functional group having a carbon-to-carbon double bond. Examples include vinyl, allyl, 1-propenyl, isopropenyl, norbornenyl, and tetracyclo[4.4.0.1^(2,5).1^(7,10)] dodecenyl.

A² is a divalent group selected from among furandiyl, tetrahydrofurandiyl and oxanorbornanediyl. Examples include furan-2,4-diyl, furan-2,5-diyl, tetrahydrofuran-2,4-diyl, tetrahydrofuran-2,5-diyl, 7-oxanorbornane-1,2-diyl, and 7-oxanorbornane-1,3-diyl.

R¹ and R² are each independently a straight, branched or cyclic monovalent hydrocarbon group having 1 to 10 carbon atoms, typically alkyl. Examples include methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, tert-amyl, n-pentyl, n-hexyl, cyclopentyl, cyclohexyl, bicyclo[2.2.1]heptyl, bicyclo[2.2.2]octyl, bicyclo[3.3.1]nonyl, bicyclo[4.4.0]decanyl, and adamantyl. Alternatively, R¹ and R², taken together, may form an aliphatic hydrocarbon ring of 3 to 20 carbon atoms, especially 4 to 15 carbon atoms, with the carbon atom to which they are bonded. Examples of the ring formed include cyclopropane, cyclobutane, cyclopentane, cyclohexane, bicyclo[2.2.1]heptane, bicyclo[2.2.2]octane, bicyclo[3.3.1]nonane, bicyclo[4.4.0]decane, and adamantane.

R³ is hydrogen or a straight, branched or cyclic monovalent hydrocarbon group having 1 to 10 carbon atoms which may contain a hetero atom, typically oxygen atom. Suitable hydrocarbon groups are alkyl, hydroxyalkyl, alkoxyalkyl, alkoxyalkoxyalkyl, alkylcarbonyl, alkoxycarbonyl, carbonyloxy, alkylcarbonyloxy, alkoxy, carbonyloxyalkyl, and alkylcarbonyloxyalkyl groups. Specific examples include hydroxymethyl, hydroxyethyl, methoxymethyl, methoxyethyl, methoxyethoxymethyl, methoxycarbonyl, formyloxy, acetoxy, pivaloyloxy, cyclohexyloxy, formyloxymethyl, acetoxymethyl, pivaloyloxymethyl, and cyclohexyloxymethyl.

Of the ester compounds of formula (1), those having the general formula (2) are preferred.

Herein R¹ and R² are as defined above, and R⁴ is hydrogen or methyl.

Of the ester compounds of formula (1), those having the general formula (3) are most preferred.

Herein R¹, R² and R⁴ are as defined above, and k¹ is 0 or 1.

Illustrative, non-limiting examples of the ester compounds of formulae (1) to (3) are given below. Note that Me is methyl and Ac is acetyl.

The ester compounds of formula (1) may be obtained, for example, as seen from the reaction scheme shown below, through the first step of forming an alcohol intermediate of formula (11) by any procedure i) to iv), and the second step of esterifying the hydroxyl group on the alcohol intermediate of formula (11) by a procedure v), although the process is not limited thereto.

Herein, A¹, A², and R¹ to R³ are as defined above. R⁵ is a halogen atom or —OR⁸. R⁶ is a divalent hydrocarbon group formed by R¹ and R² (i.e., —R¹—R²—) in the event where R¹ and R² bond together to form an aliphatic hydrocarbon ring with the carbon atom to which they are bonded. R⁷ is a hydroxyl group or halogen atom. R⁸ is methyl or ethyl. M is Li, Na, K, MgP or ZnP wherein P is a halogen atom.

Referring to the first step, the synthesis of an alcohol intermediate (11) by procedures i) to iv) is described in detail.

Procedure i) is synthesis of the alcohol intermediate (11) through nucleophilic addition reaction of an organometallic reagent (4) to a ketone compound (5).

An appropriate amount of the organometallic reagent (4) used is 0.5 to 2.0 moles, especially 0.9 to 1.2 moles per mole of the ketone compound (5). Preferred examples of solvents include ethers such as tetrahydrofuran, diethyl ether, di-n-butyl ether, and 1,4-dioxane, and hydrocarbons such as n-hexane, n-heptane, benzene, toluene, xylene and cumene. These solvents may be used alone or in admixture of any. The reaction temperature and time vary over a range depending on other reaction conditions. In one example where a Grignard reagent (corresponding to formula (4) wherein M is MgP) is used as the organometallic reagent, the reaction temperature is in a range of −20° C. to 80° C., preferably 0° C. to 50° C. It is desired for higher yields that the reaction time is determined by monitoring the reaction until the completion by gas chromatography (GC) or silica gel thin-layer chromatography (TLC). The reaction time is usually about 0.5 hour to about 10 hours. The alcohol intermediate (11) is recovered from the reaction mixture by a conventional aqueous work-up step. If necessary, the intermediate is purified by any conventional technique such as distillation or chromatography.

Procedure ii) is synthesis of the alcohol intermediate (11) through nucleophilic addition reaction of an organometallic reagent (6) to a ketone compound (7).

An appropriate amount of the organometallic reagent (6) used is 1.0 to 3.0 moles, especially 1.1 to 1.5 moles per mole of the ketone compound (7). Preferred examples of solvents include ethers such as tetrahydrofuran, diethyl ether, di-n-butyl ether, and 1,4-dioxane, and hydrocarbons such as n-hexane, n-heptane, benzene, toluene, xylene and cumene. These solvents may be used alone or in admixture of any. The reaction temperature and time vary over a range depending on other reaction conditions. In one example where a Grignard reagent (corresponding to formula (6) wherein M is MgP) is used as the organometallic reagent, the reaction temperature is in a range of −20° C. to 80° C., preferably 0° C. to 50° C. It is desired for higher yields that the reaction time is determined by monitoring the reaction until the completion by gas chromatography (GC) or silica gel thin-layer chromatography (TLC). The reaction time is usually about 0.5 hour to about 10 hours. The alcohol intermediate (11) is recovered from the reaction mixture by a conventional aqueous work-up step. If necessary, the intermediate is purified by any conventional technique such as distillation or chromatography.

Procedure iii) is synthesis of the alcohol intermediate (11) through nucleophilic addition reaction of organometallic reagents (6) and (8) to a carbonyl compound (9).

An appropriate amount of the organometallic reagents (6) and (8) used is 2.0 to 5.0 moles, especially 2.0 to 3.0 moles per mole of the carbonyl compound (9). Preferred examples of solvents include ethers such as tetrahydrofuran, diethyl ether, di-n-butyl ether, and 1,4-dioxane, and hydrocarbons such as n-hexane, n-heptane, benzene, toluene, xylene and cumene. These solvents may be used alone or in admixture of any. The reaction temperature and time vary over a range depending on other reaction conditions. In one example where Grignard reagents (corresponding to formulae (6) and (8) wherein M is MgP) are used as the organometallic reagent, the reaction temperature is in a range of 0° C. to 100° C., preferably 20° C. to 70° C. It is desired for higher yields that the reaction time is determined by monitoring the reaction until the completion by gas chromatography (GC) or silica gel thin-layer chromatography (TLC). The reaction time is usually about 0.5 hour to about 10 hours. The alcohol intermediate (11) is recovered from the reaction mixture by a conventional aqueous work-up step. If necessary, the intermediate is purified by any conventional technique such as distillation or chromatography.

Procedure iv) is taken when the alcohol intermediate of the general formula (11) is represented by the general formula (13):

that is, R¹ and R² bond together to form an aliphatic hydrocarbon ring with the carbon atom to which they are bonded, and is synthesis of the alcohol intermediate (11) through nucleophilic addition reaction of an organometallic reagent (10) to a carbonyl compound (9).

An appropriate amount of the organometallic reagent (10) used is 1.0 to 3.0 moles, especially 1.1 to 1.5 moles per mole of the carbonyl compound (9). Preferred examples of solvents include ethers such as tetrahydrofuran, diethyl ether, di-n-butyl ether, and 1,4-dioxane, and hydrocarbons such as n-hexane, n-heptane, benzene, toluene, xylene and cumene. These solvents may be used alone or in admixture of any. The reaction temperature and time vary over a range depending on other reaction conditions. In one example where a Grignard reagent (corresponding to formula (10) wherein M is MgP) is used as the organometallic reagent, the reaction temperature is in a range of 0° C. to 100° C., preferably 20° C. to 70° C. It is desired for higher yields that the reaction time is determined by monitoring the reaction until the completion by gas chromatography (GC) or silica gel thin-layer chromatography (TLC). The reaction time is usually about 0.5 hour to about 10 hours. The alcohol intermediate (11) is recovered from the reaction mixture by a conventional aqueous work-up step. If necessary, the intermediate is purified by any conventional technique such as distillation or chromatography.

The second step v) is to esterify the alcoholic hydroxyl group resulting from the first step. Esterification is readily carried out by well-known methods. In one example where an acid chloride (corresponding to formula (12) wherein R⁷ is a chlorine atom) is employed as the esterifying agent, the alcohol intermediate (11), a corresponding acid chloride such as methacrylic acid chloride or norbornenecarboxylic acid chloride and a base such as triethylamine, pyridine or 4-dimethylaminopyridine are sequentially or simultaneously added to a solvent such as methylene chloride, toluene or hexane or in a solventless system, while heating or cooling if necessary. In another example where a carboxylic acid (corresponding to formula (12) wherein R⁷ is a hydroxyl group) is employed, a condensation agent such as N,N-dicyclohexylcarbodiimide is preferably used.

In the second aspect, the present invention provides a polymer or high molecular weight compound obtained using the ester compound of formula (1) as a monomer. Therefore, the polymer comprises recurring units derived from the ester compound of formula (1).

Specifically the recurring units derived from the ester compound of formula (1) include those of the formulae (1a) to (1c) below.

Herein, A², R¹ to R⁴, and k¹ are as defined above.

In addition to the recurring units of formulae (1a) to (1c), the inventive polymers may further contain recurring units derived from any of monomers having a polymerizable double bond.

The recurring units derived from monomers having a polymerizable double bond include those of the general formulae (M1) to (M13).

Herein, R⁰⁰¹ is hydrogen, methyl or CH₂CO₂R⁰⁰³. R⁰⁰² is hydrogen, methyl or CO₂R⁰⁰³. R⁰⁰³ is a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms. R⁰⁰⁴ is hydrogen or a monovalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group. At least one of R⁰⁰⁵ to R⁰⁰⁸ represents a monovalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group while the remaining R's independently represent hydrogen or a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms. Alternatively, R⁰⁰⁵ to R⁰⁰⁸, taken together, may form a ring, and in that event, at least one of R⁰⁰⁵ to R⁰⁰⁸ is a divalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group, while the remaining R's are independently single bonds or straight, branched or cyclic alkylene groups of 1 to 15 carbon atoms. R⁰⁰⁹ is a monovalent hydrocarbon group of 2 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide. At least one of R⁰¹⁰ to R⁰¹³ is a monovalent hydrocarbon group of 2 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide, while the remaining R's are independently hydrogen or straight, branched or cyclic alkyl groups of 1 to 15 carbon atoms. R⁰¹⁰ to R⁰¹³, taken together, may form a ring, and in that event, at least one of R⁰¹⁰ to R⁰¹³ is a divalent hydrocarbon group of 1 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide, while the remaining R's are independently single bonds or straight, branched or cyclic alkylene groups of 1 to 15 carbon atoms. R⁰¹⁴ is a polycyclic hydrocarbon group having 7 to 15 carbon atoms or an alkyl group containing a polycyclic hydrocarbon group. R015 is an acid labile group. X is CH₂ or an oxygen atom or sulfur atom. Y′ is —O— or —(NR^(f))—. R^(f) is hydrogen atom or a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms. Letter k is 0 or 1.

More illustratively, R⁰⁰¹ is hydrogen, methyl or CH₂CO₂R⁰⁰³. R⁰⁰² is hydrogen, methyl or CO₂R⁰⁰³. R⁰⁰³ is a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms, for example, methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, tert-amyl, n-pentyl, n-hexyl, cyclopentyl, cyclohexyl, ethylcyclopentyl, butylcyclopentyl, ethylcyclohexyl, butylcyclohexyl, adamantyl, ethyladamantyl, and butyladamantyl.

R⁰⁰⁴ is hydrogen or a monovalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group, for example, hydrogen, carboxyethyl, carboxybutyl, carboxycyclopentyl, carboxycyclohexyl, carboxynorbornyl, carboxyadamantyl, hydroxyethyl, hydroxybutyl, hydroxycyclopentyl, hydroxycyclohexyl, hydroxynorbornyl, and hydroxyadamantyl.

At least one of R⁰⁰⁵ to R⁰⁰⁸ represents a monovalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group while the remaining R's independently represent hydrogen or a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms. Examples of the carboxyl or hydroxyl-bearing monovalent hydrocarbon group of 1 to 15 carbon atoms include carboxy, carboxymethyl, carboxyethyl, carboxybutyl, hydroxymethyl, hydroxyethyl, hydroxybutyl, 2-carboxyethoxycarbonyl, 4-carboxybutoxycarbonyl, 2-hydroxyethoxycarbonyl, 4-hydroxybutoxycarbonyl, carboxycyclopentyloxycarbonyl, carboxycyclohexyloxycarbonyl, carboxynorbornyloxycarbonyl, carboxyadamantyloxycarbonyl, hydroxycyclopentyloxycarbonyl, hydroxycyclohexyloxycarbonyl, hydroxynorbornyloxycarbonyl, and hydroxyadamantyloxycarbonyl. Examples of the straight, branched or cyclic alkyl group of 1 to 15 carbon atoms include methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, tert-amyl, n-pentyl, n-hexyl, cyclopentyl, cyclohexyl, ethylcyclopentyl, butylcyclopentyl, ethylcyclohexyl, butylcyclohexyl, adamantyl, ethyladamantyl, and butyladamantyl.

Alternatively, R⁰⁰⁵ to R⁰⁰⁸, taken together, may form a ring, and in that event, at least one of R⁰⁰⁵ to R⁰⁰⁸ is a divalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group, while the remaining R's are independently single bonds or straight, branched or cyclic alkylene groups of 1 to 15 carbon atoms. Examples of the carboxyl or hydroxyl-bearing divalent hydrocarbon group of 1 to 15 carbon atoms include the above-exemplified carboxyl or hydroxyl-bearing monovalent hydrocarbon groups, with one hydrogen atom eliminated therefrom. Examples of the straight, branched or cyclic alkylene groups of 1 to 15 carbon atoms include the above-exemplified straight, branched or cyclic alkyl groups of 1 to 15 carbon atoms, with one hydrogen atom eliminated therefrom.

R⁰⁰⁹ is a monovalent hydrocarbon group of 2 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide. Examples of such hydrocarbon groups include methoxymethyl, methoxyethoxymethyl, 2-oxooxolan-3-yl, 2-oxooxolan-4-yl, 4,4-dimethyl-2-oxooxolan-3-yl, 4-methyl-2-oxooxan-4-yl, 2-oxo-1,3-dioxolan-4-ylmethyl, and 5-methyl-2-oxooxolan-5-yl, as well as the groups shown below.

In these formulae and throughout the specification, the broken line denotes a free valence bond, Me is methyl, and Et is ethyl.

At least one of R⁰¹⁰ to R⁰¹³ is a monovalent hydrocarbon group of 2 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide, while the remaining R's are independently hydrogen or straight, branched or cyclic alkyl groups of 1 to 15 carbon atoms. Examples of the monovalent hydrocarbon group of 2 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide include methoxymethyl, methoxymethoxymethyl, formyl, methylcarbonyl, formyloxy, acetoxy, pivaloyloxy, formyloxymethyl, acetoxymethyl, pivaloyloxymethyl, methoxycarbonyl, 2-oxooxolan-3-yloxycarbonyl, 4,4-dimethyl-2-oxooxolan-3-yloxycarbonyl, 4-methyl-2-oxooxan-4-yloxycarbonyl, 2-oxo-1,3-dioxolan-4-ylmethyloxycarbonyl, and 5-methyl-2-oxooxolan-5-yloxycarbonyl, as well as the groups shown below.

Examples of the straight, branched or cyclic alkyl groups of 1 to 15 carbon atoms are the same as exemplified for R⁰⁰³.

R⁰¹⁰ to R⁰¹³, taken together, may form a ring, and in that event, at least one of R⁰¹⁰ to R⁰¹³ is a divalent hydrocarbon group of 1 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide, while the remaining R's are independently single bonds or straight, branched or cyclic alkylene groups of 1 to 15 carbon atoms. Examples of the divalent hydrocarbon group of 1 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide include 2-oxapropane-1,3-diyl, 1,1-dimethyl-2-oxapropane-1,3-diyl, 1-oxo-2-oxapropane-1,3-diyl, 1,3-dioxo-2-oxapropane-1,3-diyl, 1-oxo-2-oxabutane-1,4-diyl, and 1,3-dioxo-2-oxabutane-1,4-diyl, as well as the groups exemplified as the monovalent hydrocarbon group of 1 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide, with one hydrogen atom eliminated therefrom. Examples of the straight, branched or cyclic alkylene groups of 1 to 15 carbon atoms include the groups exemplified for R⁰⁰³, with one hydrogen atom eliminated therefrom.

R⁰¹⁴ is a polycyclic hydrocarbon group having 7 to 15 carbon atoms or an alkyl group containing a polycyclic hydrocarbon group, for example, norbornyl, bicyclo[3.3.1]nonyl, tricyclo[5.2.1.0^(2,6)]decyl, adamantyl, methyladamantyl, ethyladamantyl, butyladamantyl, norbornylmethyl, and adamantylmethyl.

R⁰¹⁵ is an acid labile group. Suitable acid labile groups include groups of the following general formulae (L1) to (L4), tertiary alkyl groups of 4 to 20 carbon atoms, preferably 4 to 15 carbon atoms, trialkylsilyl groups in which each alkyl moiety has 1 to 6 carbon atoms, and oxoalkyl groups of 4 to 20 carbon atoms.

R^(L01) and R^(L02) are hydrogen or straight, branched or cyclic alkyl groups of 1 to 18 carbon atoms, preferably 1 to 10 carbon atoms. Exemplary alkyl groups include methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, cyclopentyl, cyclohexyl, 2-ethylhexyl, and n-octyl. R^(L03) is a monovalent hydrocarbon group of 1 to 18 carbon atoms, preferably 1 to 10 carbon atoms, which may contain a hetero atom such as oxygen, examples of which include unsubstituted straight, branched or cyclic alkyl groups and straight, branched or cyclic alkyl groups in which some hydrogen atoms are replaced by hydroxyl, alkoxy, oxo, amino, alkylamino or the like. Illustrative examples are the substituted alkyl groups shown below.

A pair of R^(L01) and R^(L02), R^(L01) and R^(L03), or R^(L02) and R^(L03) may bond together to form a ring. Each of R^(L01), R^(L02) and R^(L03) is a straight or branched alkylene group of 1 to 18 carbon atoms, preferably 1 to 10 carbon atoms when they form a ring.

R^(L04) is a tertiary alkyl group of 4 to 20 carbon atoms, preferably 4 to 15 carbon atoms, a trialkylsilyl group in which each alkyl moiety has 1 to 6 carbon atoms, an oxoalkyl group of 4 to 20 carbon atoms, or a group of formula (L1). Exemplary tertiary alkyl groups are tert-butyl, tert-amyl, 1,1-diethylpropyl, 2-cyclopentylpropan-2-yl, 2-cyclohexylpropan-2-yl, 2-(bicyclo[2.2.1]heptan-2-yl)propan-2-yl, 2-(adamantan-1-yl)propan-2-yl, 1-ethylcyclopentyl, 1-butylcyclopentyl, 1-ethylcyclohexyl, 1-butylcyclohexyl, 1-ethyl-2-cyclopentenyl, 1-ethyl-2-cyclohexenyl, 2-methyl-2-adamantyl, and 2-ethyl-2-adamantyl. Exemplary trialkylsilyl groups are trimethylsilyl, triethylsilyl, and dimethyl-tert-butylsilyl. Exemplary oxoalkyl groups are 3-oxocyclohexyl, 4-methyl-2-oxooxan-4-yl, and 5-methyl-2-oxooxolan-5-yl. Letter y is an integer of 0 to 6.

R^(L05) is a monovalent hydrocarbon group of 1 to 8 carbon atoms which may contain a hetero atom or a substituted or unsubstituted aryl group of 6 to 20 carbon atoms. Examples of the monovalent hydrocarbon group which may contain a hetero atom include straight, branched or cyclic alkyl groups such as methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, tert-amyl, n-pentyl, n-hexyl, cyclopentyl, and cyclohexyl, and substituted groups in which some hydrogen atoms on the foregoing groups are substituted with hydroxyl, alkoxy, carboxy, alkoxycarbonyl, oxo, amino, alkylamino, cyano, mercapto, alkylthio, sulfo or other groups. Exemplary aryl groups are phenyl, methylphenyl, naphthyl, anthryl, phenanthryl, and pyrenyl. Letter m is equal to 0 or 1, n is equal to 0, 1, 2 or 3, and 2m+n is equal to 2 or 3.

R^(L06) is a monovalent hydrocarbon group of 1 to 8 carbon atoms which may contain a hetero atom or a substituted or unsubstituted aryl group of 6 to 20 carbon atoms. Examples of these groups are the same as exemplified for R^(L05).

R^(L07) to R^(L16) independently represent hydrogen or monovalent hydrocarbon groups of 1 to 15 carbon atoms which may contain a hetero atom. Exemplary hydrocarbon groups are straight, branched or cyclic alkyl groups such as methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, tert-amyl, n-pentyl, n-hexyl, n-octyl, n-nonyl, n-decyl, cyclopentyl, cyclohexyl, cyclopentylmethyl, cyclopentylethyl, cyclopentylbutyl, cyclohexylmethyl, cyclohexylethyl and cyclohexylbutyl, and substituted ones of these groups in which some hydrogen atoms are replaced by hydroxyl, alkoxy, carboxy, alkoxycarbonyl, oxo, amino, alkylamino, cyano, mercapto, alkylthio, sulfo or other groups. Alternatively, R^(L07) to R^(L16), taken together, form a ring (for example, a pair of R^(L07) and R^(L08), R^(L07) and R^(L09), R^(L08) and R^(L10), R^(L09) and R^(L10), R^(L11) and R^(L12), R^(L13) and R^(L14), or a similar pair form a ring). Each of R^(L07) to R^(L16) represents a divalent C₁-C₁₅ hydrocarbon group which may contain a hetero atom, when they form a ring, examples of which are the ones exemplified above for the monovalent hydrocarbon groups, with one hydrogen atom being eliminated. Two of R^(L07) to R^(L16) which are attached to adjoining carbon atoms (for example, a pair of R^(L07) and R^(L09), R^(L09) and R^(L15), R^(L13) and R^(L15), or a similar pair) may bond together directly to form a double bond.

Of the acid labile groups of formula (L1), the straight and branched ones are exemplified by the following groups.

Of the acid labile groups of formula (L1), the cyclic ones are, for example, tetrahydrofuran-2-yl, 2-methyltetrahydrofuran-2-yl, tetrahydropyran-2-yl, and 2-methyltetrahydropyran-2-yl.

Examples of the acid labile groups of formula (L2) include tert-butoxycarbonyl, tert-butoxycarbonylmethyl, tert-amyloxycarbonyl, tert-amyloxycarbonylmethyl, 1,1-diethylpropyloxycarbonyl, 1,1-diethylpropyloxycarbonylmethyl, 1-ethylcyclopentyloxycarbonyl, 1-ethylcyclopentyloxycarbonylmethyl, 1-ethyl-2-cyclopentenyloxycarbonyl, 1-ethyl-2-cyclopentenyloxycarbonylmethyl, 1-ethoxyethoxycarbonylmethyl, 2-tetrahydropyranyloxycarbonylmethyl, and 2-tetrahydrofuranyloxycarbonylmethyl groups.

Examples of the acid labile groups of formula (L3) include 1-methylcyclopentyl, 1-ethylcyclopentyl, 1-n-propylcyclopentyl, 1-isopropylcyclopentyl, 1-n-butylcyclopentyl, 1-sec-butylcyclopentyl, 1-cyclohexylcyclopentyl, 1-(4-methoxy-n-butyl)cyclopentyl, 1-methylcyclohexyl, 1-ethylcyclohexyl, 3-methyl-l-cyclopenten-3-yl, 3-ethyl-1-cyclopenten-3-yl, 3-methyl-1-cyclohexen-3-yl, and 3-ethyl-1-cyclohexen-3-yl groups.

The acid labile groups of formula (L4) are exemplified by the following groups.

Examples of the tertiary alkyl groups of 4 to 20 carbon atoms, trialkylsilyl groups in which each alkyl moiety has 1 to 6 carbon atoms, and oxoalkyl groups of 4 to 20 carbon atoms are as exemplified for R^(L04).

Referring back to formulae (M1) to (M13), X is CH₂ or an oxygen atom or sulfur atom. Y′ is —O— or —(NR^(f))—. R^(f) is hydrogen atom or straight, branched or cyclic alkyl groups of 1 to 15 carbon atoms. Letter k is 0 or 1.

In addition to the recurring units described above, recurring units originating from any of other monomers having a carbon-to-carbon double bond may be introduced into the inventive polymer. Illustrative examples of such additional compounds are substituted acrylates such as methyl methacrylate, methyl crotonate, dimethyl maleate, and dimethyl itaconate; unsaturated carboxylic acids such as maleic acid, fumaric acid, and itaconic acid; substituted norbornenes such as norbornene and methyl norbornene-5-carboxylate; and unsaturated acid anhydrides such as itaconic anhydride.

The polymer of the invention should preferably have a weight average molecular weight (Mw) of about 1,000 to about 500,000, more preferably about 3,000 to about 100,000, as measured by gel permeation chromatography (GPC) using polystyrene standards. Outside the range, there may arise problems such as an extreme lowering of etching resistance and a lowering of resolution due to a failure to have a difference in dissolution rate before and after exposure.

In the polymers of the invention, the preferred proportion of recurring units based on the respective monomers is in the following range (in mol %), though not limited thereto. The polymers contain: (i) more than 0 mol % to 100 mol %, preferably 10 to 80 mol %, and more preferably 20 to 60 mol % of constituent units of formulae (1a) to (1c) derived from the monomer of formula (1), (ii) 0 mol % to less than 100 mol %, preferably 1 to 95 mol %, and more preferably 40 to 80 mol % of constituent units of one or more types of formulae (M1) to (M13), and optionally, (iii) 0 to 80 mol %, preferably 0 to 70 mol %, and more preferably 0 to 50 mol % of constituent units of one or more types derived from another monomer or monomers.

The polymers of the invention can be prepared by a variety of copolymerization reaction methods using the compound of formula (1) as a first monomer and compounds having a polymerizable double bond as second and subsequent monomers. The preferred polymerization reaction is radical polymerization, anionic polymerization or coordination polymerization.

For radical polymerization, preferred reaction conditions include (a) a solvent selected from among hydrocarbons such as benzene, ethers such as tetrahydrofuran, alcohols such as ethanol, and ketones such as methyl isobutyl ketone, (b) a polymerization initiator selected from azo compounds such as 2,2′-azobisisobutyronitrile and peroxides such as benzoyl peroxide and lauroyl peroxide, (c) a temperature of about 0° C. to about 100° C., and (d) a time of about ½ hour to about 48 hours. Reaction conditions lo outside the described range may be employed if desired.

For anionic polymerization, preferred reaction conditions include (a) a solvent selected from among hydrocarbons such as benzene, ethers such as tetrahydrofuran, and liquid ammonia, (b) a polymerization initiator selected from metals such as sodium and potassium, alkyl metals such as n-butyllithium and sec-butyllithium, ketyl, and Grignard reagents, (c) a temperature of about −78° C. to about 0° C., (d) a time of about ½ hour to about 48 hours, and (e) a stopper selected from among proton-donative compounds such as methanol, halides such as methyl iodide, and electrophilic compounds. Reaction conditions outside the described range may be employed if desired.

For coordination polymerization, preferred reaction conditions include (a) a solvent selected from among hydrocarbons such as n-heptane and toluene, (b) a catalyst selected from Ziegler-Natta catalysts comprising a transition metal (e.g., titanium) and alkylaluminum, Phillips catalysts of metal oxides having chromium or nickel compounds carried thereon, and olefin-metathesis mixed catalysts as typified by tungsten and rhenium mixed catalysts, (c) a temperature of about 0° C. to about 100° C., and (d) a time of about ½ hour to about 48 hours. Reaction conditions outside the described range may be employed if desired.

Resist Composition

Since the polymer of the invention is useful as the base resin of a resist composition, the other aspect of the invention provides a resist composition, especially a chemically amplified positive resist composition, comprising the polymer. Typically, the resist composition contains the polymer, a photoacid generator, and an organic solvent, and other optional components.

Photoacid Generator

The photoacid generator is a compound capable of generating an acid upon exposure to high energy radiation or electron beams and includes the following:

(i) onium salts of the formula (P1a-1), (P1a-2) or (P1b),

(ii) diazomethane derivatives of the formula (P2),

(iii) glyoxime derivatives of the formula (P3),

(iv) bissulfone derivatives of the formula (P4),

(v) sulfonic acid esters of N-hydroxyimide compounds of the formula (P5),

(vi) β-ketosulfonic acid derivatives,

(vii) disulfone derivatives,

(viii) nitrobenzylsulfonate derivatives,

(ix) sulfonate derivatives, and

(x) oxime sulfonates.

These photoacid generators are described in detail. (i) Onium Salts of Formula (P1a-1), (P1a-2) or (P1b):

Herein, R^(101a), R^(101b), and R^(101c) independently represent straight, branched or cyclic alkyl, alkenyl, oxoalkyl or oxoalkenyl groups of 1 to 12 carbon atoms, aryl groups of 6 to 20 carbon atoms, or aralkyl or aryloxoalkyl groups of 7 to 12 carbon atoms, wherein some or all of the hydrogen atoms may be replaced by alkoxy or other groups. Also, R^(101b) and R^(101c), taken together, may form a ring. R^(101b) and R^(101c) each are alkylene groups of 1 to 6 carbon atoms when they form a ring. K⁻ is a non-nucleophilic counter ion.

R^(101a), R^(101b), and R^(101c) may be the same or different and are illustrated below. Exemplary alkyl groups include methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, pentyl, hexyl, heptyl, octyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclopropylmethyl, 4-methylcyclohexyl, cyclohexylmethyl, norbornyl, and adamantyl. Exemplary alkenyl groups include vinyl, allyl, propenyl, butenyl, hexenyl, and cyclohexenyl. Exemplary oxoalkyl groups include 2-oxocyclopentyl and 2-oxocyclohexyl as well as 2-oxopropyl, 2-cyclopentyl-2-oxoethyl, 2-cyclohexyl-2-oxoethyl, and 2-(4-methylcyclohexyl)-2-oxoethyl. Exemplary aryl groups include phenyl and naphthyl; alkoxyphenyl groups such as p-methoxyphenyl, m-methoxyphenyl, o-methoxyphenyl, ethoxyphenyl, p-tert-butoxyphenyl, and m-tert-butoxyphenyl; alkylphenyl groups such as 2-methylphenyl, 3-methylphenyl, 4-methylphenyl, ethylphenyl, 4-tert-butylphenyl, 4-butylphenyl, and dimethylphenyl; alkylnaphthyl groups such as methylnaphthyl and ethylnaphthyl; alkoxynaphthyl groups such as methoxynaphthyl and ethoxynaphthyl; dialkylnaphthyl groups such as dimethylnaphthyl and diethylnaphthyl; and dialkoxynaphthyl groups such as dimethoxynaphthyl and diethoxynaphthyl. Exemplary aralkyl groups include benzyl, phenylethyl, and phenethyl. Exemplary aryloxoalkyl groups are 2-aryl-2-oxoethyl groups such as 2-phenyl-2-oxoethyl, 2-(1-naphthyl)-2-oxoethyl, and 2-(2-naphthyl)-2-oxoethyl. Examples of the non-nucleophilic counter ion represented by K⁻ include halide ions such as chloride and bromide ions, fluoroalkylsulfonate ions such as triflate, 1,1,1-trifluoroethanesulfonate, and nonafluorobutanesulfonate, arylsulfonate ions such as tosylate, benzenesulfonate, 4-fluorobenzenesulfonate, and 1,2,3,4,5-pentafluorobenzenesulfonate, and alkylsulfonate ions such as mesylate and butanesulfonate.

Herein, R^(102a) and R^(102b) independently represent straight, branched or cyclic alkyl groups of 1 to 8 carbon atoms. R¹⁰³ represents a straight, branched or cyclic alkylene groups of 1 to 10 carbon atoms. R^(104a) and R^(104b) independently represent 2-oxoalkyl groups of 3 to 7 carbon atoms. K⁻ is a non-nucleophilic counter ion.

Illustrative of the groups represented by R^(102a) and R^(102b) are methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, pentyl, hexyl, heptyl, octyl, cyclopentyl, cyclohexyl, cyclopropylmethyl, 4-methylcyclohexyl, and cyclohexylmethyl. Illustrative of the groups represented by R¹⁰³ are methylene, ethylene, propylene, butylene, pentylene, hexylene, heptylene, octylene, nonylene, 1,4-cyclohexylene, 1,2-cyclohexylene, 1,3-cyclopentylene, 1,4-cyclooctylene, and 1,4-cyclohexanedimethylene. Illustrative of the groups represented by R^(104a) and R^(104b) are 2-oxopropyl, 2-oxocyclopentyl, 2-oxocyclohexyl, and 2-oxocycloheptyl. Illustrative examples of the counter ion represented by K⁻ are the same as exemplified for formulae (P1a-1) and (P1a-2). (ii) Diazomethane Derivatives of Formula (P2)

Herein, R¹⁰⁵ and R¹⁰⁶ independently represent straight, branched or cyclic alkyl or halogenated alkyl groups of 1 to 12 carbon atoms, aryl or halogenated aryl groups of 6 to 20 carbon atoms, or aralkyl groups of 7 to 12 carbon atoms.

Of the groups represented by R¹⁰⁵ and R¹⁰⁶, exemplary alkyl groups include methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, pentyl, hexyl, heptyl, octyl, amyl, cyclopentyl, cyclohexyl, cycloheptyl, norbornyl, and adamantyl. Exemplary halogenated alkyl groups include trifluoromethyl, 1,1,1-trifluoroethyl, 1,1,1-trichloroethyl, and nonafluorobutyl. Exemplary aryl groups include phenyl; alkoxyphenyl groups such as p-methoxyphenyl, m-methoxyphenyl, o-methoxyphenyl, ethoxyphenyl, p-tert-butoxyphenyl, and m-tert-butoxyphenyl; and alkylphenyl groups such as 2-methylphenyl, 3-methylphenyl, 4-methylphenyl, ethylphenyl, 4-tert-butylphenyl, 4-butylphenyl, and dimethylphenyl. Exemplary halogenated aryl groups include fluorophenyl, chlorophenyl, and 1,2,3,4,5-pentafluorophenyl. Exemplary aralkyl groups include benzyl and phenethyl. (iii) Glyoxime Derivatives of Formula (P3)

Herein, R¹⁰⁵ is as defined above. R¹⁰⁷, R¹⁰⁸, and R¹⁰⁹ independently represent straight, branched or cyclic alkyl or halogenated alkyl groups of 1 to 12 carbon atoms, aryl or halogenated aryl groups of 6 to 20 carbon atoms, or aralkyl groups of 7 to 12 carbon atoms. Also, R¹⁰⁸ and R¹⁰⁹, taken together, may form a ring. R¹⁰⁸ and R¹⁰⁹ each are straight or branched alkylene groups of 1 to 6 carbon atoms when they form a ring.

Illustrative examples of the alkyl, halogenated alkyl, aryl, halogenated aryl, and aralkyl groups represented by R¹⁰⁷, R¹⁰⁸, and R¹⁰⁹ are the same as exemplified for R¹⁰⁵ and R¹⁰⁶. Examples of the alkylene groups represented by R¹⁰⁸ and R¹⁰⁹ include methylene, ethylene, propylene, butylene, and hexylene. (iv) Bissulfone Derivatives of Formula (P4)

Herein, R^(101a) and R^(101b) are as defined above. (v) Sulfonic Acid Esters of N-hydroxyimide Compounds of Formula (P5)

Herein, R¹¹⁰ is an arylene group of 6 to 10 carbon atoms, alkylene group of 1 to 6 carbon atoms, or alkenylene group of 2 to 6 carbon atoms wherein some or all of the hydrogen atoms may be replaced by straight or branched alkyl or alkoxy groups of 1 to 4 carbon atoms, nitro, acetyl, or phenyl groups. R¹¹¹ is a straight, branched or cyclic alkyl group of 1 to 8 carbon atoms, alkenyl, alkoxyalkyl, phenyl or naphthyl group wherein some or all of the hydrogen atoms may be replaced by alkyl or alkoxy groups of 1 to 4 carbon atoms, phenyl groups (which may have substituted thereon an alkyl or alkoxy of 1 to 4 carbon atoms, nitro, or acetyl group), hetero-aromatic groups of 3 to 5 carbon atoms, or chlorine or fluorine atoms.

Of the groups represented by R¹¹⁰, exemplary arylene groups include 1,2-phenylene and 1,8-naphthylene; exemplary alkylene groups include methylene, ethylene, trimethylene, tetramethylene, phenylethylene, and norbornane-2,3-diyl; and exemplary alkenylene groups include 1,2-vinylene, 1-phenyl-1,2-vinylene, and 5-norbornene-2,3-diyl. Of the groups represented by R¹¹¹, exemplary alkyl groups are as exemplified for R^(101a) to R^(101c); exemplary alkenyl groups include vinyl, 1-propenyl, allyl, 1-butenyl, 3-butenyl, isoprenyl, 1-pentenyl, 3-pentenyl, 4-pentenyl, dimethylallyl, 1-hexenyl, 3-hexenyl, 5-hexenyl, 1-heptenyl, 3-heptenyl, 6-heptenyl, and 7-octenyl; and exemplary alkoxyalkyl groups include methoxymethyl, ethoxymethyl, propoxymethyl, butoxymethyl, pentyloxymethyl, hexyloxymethyl, heptyloxymethyl, methoxyethyl, ethoxyethyl, propoxyethyl, butoxyethyl, pentyloxyethyl, hexyloxyethyl, methoxypropyl, ethoxypropyl, propoxypropyl, butoxypropyl, methoxybutyl, ethoxybutyl, propoxybutyl, methoxypentyl, ethoxypentyl, methoxyhexyl, and methoxyheptyl.

Of the substituents on these groups, the alkyl groups of 1 to 4 carbon atoms include methyl, ethyl, propyl, isopropyl, n-butyl, isobutyl and tert-butyl; and the alkoxy groups of 1 to 4 carbon atoms include methoxy, ethoxy, propoxy, isopropoxy, n-butoxy, isobutoxy, and tert-butoxy. The phenyl groups which may have substituted thereon an alkyl or alkoxy of 1 to 4 carbon atoms, nitro, or acetyl group include phenyl, tolyl, p-tert-butoxyphenyl, p-acetylphenyl and p-nitrophenyl. The hetero-aromatic groups of 3 to 5 carbon atoms include pyridyl and furyl.

Illustrative examples of the photoacid generator include:

onium salts such as

diphenyliodonium trifluoromethanesulfonate,

(p-tert-butoxyphenyl)phenyliodonium trifluoromethanesulfonate,

diphenyliodonium p-toluenesulfonate,

(p-tert-butoxyphenyl)phenyliodonium p-toluenesulfonate,

triphenylsulfonium trifluoromethanesulfonate,

(p-tert-butoxyphenyl)diphenylsulfonium trifluoromethanesulfonate,

bis(p-tert-butoxyphenyl)phenylsulfonium trifluoromethanesulfonate,

tris(p-tert-butoxyphenyl)sulfonium trifluoromethanesulfonate,

triphenylsulfonium p-toluenesulfonate,

(p-tert-butoxyphenyl)diphenylsulfonium p-toluenesulfonate,

bis(p-tert-butoxyphenyl)phenylsulfonium p-toluenesulfonate,

tris(p-tert-butoxyphenyl)sulfonium p-toluenesulfonate,

triphenylsulfonium nonafluorobutanesulfonate,

triphenylsulfonium butanesulfonate,

trimethylsulfonium trifluoromethanesulfonate,

trimethylsulfonium p-toluenesulfonate,

cyclohexylmethyl(2-oxocyclohexyl)sulfonium trifluoromethanesulfonate,

cyclohexylmethyl(2-oxocyclohexyl)sulfonium p-toluenesulfonate,

dimethylphenylsulfonium trifluoromethanesulfonate,

dimethylphenylsulfonium p-toluenesulfonate,

dicyclohexylphenylsulfonium trifluoromethanesulfonate,

dicyclohexylphenylsulfonium p-toluenesulfonate,

trinaphthylsulfonium trifluoromethanesulfonate,

cyclohexylmethyl(2-oxocyclohexyl)sulfonium trifluoromethanesulfonate,

(2-norbornyl)methyl(2-oxocyclohexyl)sulfonium trifluoromethanesulfonate,

ethylenebis[methyl(2-oxocyclopentyl)sulfonium trifluoromethanesulfonate], and

1,2′-naphthylcarbonylmethyltetrahydrothiophenium triflate;

diazomethane derivatives such as

bis(benzenesulfonyl)diazomethane,

bis(p-toluenesulfonyl)diazomethane,

bis(xylenesulfonyl)diazomethane,

bis(cyclohexylsulfonyl)diazomethane,

bis(cyclopentylsulfonyl)diazomethane,

bis(n-butylsulfonyl)diazomethane,

bis(isobutylsulfonyl)diazomethane,

bis(sec-butylsulfonyl)diazomethane,

bis(n-propylsulfonyl)diazomethane,

bis(isopropylsulfonyl)diazomethane,

bis(tert-butylsulfonyl)diazomethane,

bis(n-amylsulfonyl)diazomethane,

bis(isoamylsulfonyl)diazomethane,

bis(sec-amylsulfonyl)diazomethane,

bis(tert-amylsulfonyl)diazomethane,

1-cyclohexylsulfonyl-1-(tert-butylsulfonyl)diazomethane,

1-cyclohexylsulfonyl-1-(tert-amylsulfonyl)diazomethane, and

1-tert-amylsulfonyl-1-(tert-butylsulfonyl)diazomethane;

glyoxime derivatives such as

bis-O-(p-toluenesulfonyl)-α-dimethylglyoxime,

bis-O-(p-toluenesulfonyl)-α-diphenylglyoxime,

bis-O-(p-toluenesulfonyl)-α-dicyclohexylglyoxime,

bis-O-(p-toluenesulfonyl)-2,3-pentanedioneglyoxime,

bis-O-(p-toluenesulfonyl)-2-methyl-3,4-pentanedioneglyoxime,

bis-O-(n-butanesulfonyl)-α-dimethylglyoxime,

bis-O-(n-butanesulfonyl)-α-diphenylglyoxime,

bis-O-(n-butanesulfonyl)-α-dicyclohexylglyoxime,

bis-O-(n-butanesulfonyl)-2,3-pentanedioneglyoxime,

bis-O-(n-butanesulfonyl)-2-methyl-3,4-pentanedioneglyoxime,

bis-O-(methanesulfonyl)-α-dimethylglyoxime,

bis-O-(trifluoromethanesulfonyl)-α-dimethylglyoxime,

bis-O-(1,1,1-trifluoroethanesulfonyl)-α-dimethylglyoxime,

bis-O-(tert-butanesulfonyl)-α-dimethylglyoxime,

bis-O-(perfluorooctanesulfonyl)-α-dimethylglyoxime,

bis-O-(cyclohexanesulfonyl)-α-dimethylglyoxime,

bis-O-(benzenesulfonyl)-α-dimethylglyoxime,

bis-O-(p-fluorobenzenesulfonyl)-α-dimethylglyoxime,

bis-O-(p-tert-butylbenzenesulfonyl)-α-dimethylglyoxime,

bis-O-(xylenesulfonyl)-α-dimethylglyoxime, and

bis-O-(camphorsulfonyl)-α-dimethylglyoxime;

bissulfone derivatives such as

bisnaphthylsulfonylmethane, bistrifluoromethylsulfonylmethane,

bismethylsulfonylmethane, bisethylsulfonylmethane,

bispropylsulfonylmethane, bisisopropylsulfonylmethane,

bis-p-toluenesulfonylmethane, and bisbenzenesulfonylmethane;

β-ketosulfone derivatives such as

2-cyclohexylcarbonyl-2-(p-toluenesulfonyl)propane and

2-isopropylcarbonyl-2-(p-toluenesulfonyl)propane;

nitrobenzyl sulfonate derivatives such as

2,6-dinitrobenzyl p-toluenesulfonate and

2,4-dinitrobenzyl p-toluenesulfonate;

sulfonic acid ester derivatives such as

1,2,3-tris(methanesulfonyloxy)benzene,

1,2,3-tris(trifluoromethanesulfonyloxy)benzene, and

1,2,3-tris(p-toluenesulfonyloxy)benzene; and

sulfonic acid esters of N-hydroxyimides such as

N-hydroxysuccinimide methanesulfonate,

N-hydroxysuccinimide trifluoromethanesulfonate,

N-hydroxysuccinimide ethanesulfonate,

N-hydroxysuccinimide 1-propanesulfonate,

N-hydroxysuccinimide 2-propanesulfonate,

N-hydroxysuccinimide 1-pentanesulfonate,

N-hydroxysuccinimide 1-octanesulfonate,

N-hydroxysuccinimide p-toluenesulfonate,

N-hydroxysuccinimide p-methoxybenzenesulfonate,

N-hydroxysuccinimide 2-chloroethanesulfonate,

N-hydroxysuccinimide benzenesulfonate,

N-hydroxysuccinimide 2,4,6-trimethylbenzenesulfonate,

N-hydroxysuccinimide 1-naphthalenesulfonate,

N-hydroxysuccinimide 2-naphthalenesulfonate,

N-hydroxy-2-phenylsuccinimide methanesulfonate,

N-hydroxymaleimide methanesulfonate,

N-hydroxymaleimide ethanesulfonate,

N-hydroxy-2-phenylmaleimide methanesulfonate,

N-hydroxyglutarimide methanesulfonate,

N-hydroxyglutarimide benzenesulfonate,

N-hydroxyphthalimide methanesulfonate,

N-hydroxyphthalimide benzenesulfonate,

N-hydroxyphthalimide trifluoromethanesulfonate,

N-hydroxyphthalimide p-toluenesulfonate,

N-hydroxynaphthalimide methanesulfonate,

N-hydroxynaphthalimide benzenesulfonate,

N-hydroxy-5-norbornene-2,3-dicarboxyimide methanesulfonate,

N-hydroxy-5-norbornene-2,3-dicarboxyimide trifluoromethanesulfonate, and

N-hydroxy-5-norbornene-2,3-dicarboxyimide p-toluenesulfonate.

Preferred among these photoacid generators are onium salts such as

triphenylsulfonium trifluoromethanesulfonate,

(p-tert-butoxyphenyl)diphenylsulfonium trifluoromethanesulfonate,

tris(p-tert-butoxyphenyl)sulfonium trifluoromethanesulfonate,

triphenylsulfonium p-toluenesulfonate,

(p-tert-butoxyphenyl)diphenylsulfonium p-toluenesulfonate,

tris(p-tert-butoxyphenyl)sulfonium p-toluenesulfonate,

trinaphthylsulfonium trifluoromethanesulfonate,

cyclohexylmethyl(2-oxocyclohexyl)sulfonium trifluoromethanesulfonate,

(2-norbornyl)methyl(2-oxocylohexyl)sulfonium trifluoromethanesulfonate, and

1,2′-naphthylcarbonylmethyltetrahydrothiophenium triflate;

diazomethane derivatives such as

bis(benzenesulfonyl)diazomethane,

bis(p-toluenesulfonyl)diazomethane,

bis(cyclohexylsulfonyl)diazomethane,

bis(n-butylsulfonyl)diazomethane,

bis(isobutylsulfonyl)diazomethane,

bis(sec-butylsulfonyl)diazomethane,

bis(n-propylsulfonyl)diazomethane,

bis(isopropylsulfonyl)diazomethane, and

bis(tert-butylsulfonyl)diazomethane;

glyoxime derivatives such as

bis-O-(p-toluenesulfonyl)-α-dimethylglyoxime and

bis-O-(n-butanesulfonyl)-α-dimethylglyoxime;

bissulfone derivatives such as bisnaphthylsulfonylmethane;

and sulfonic acid esters of N-hydroxyimide compounds such as

N-hydroxysuccinimide methanesulfonate,

N-hydroxysuccinimide trifluoromethanesulfonate,

N-hydroxysuccinimide 1-propanesulfonate,

N-hydroxysuccinimide 2-propanesulfonate,

N-hydroxysuccinimide 1-pentanesulfonate,

N-hydroxysuccinimide p-toluenesulfonate,

N-hydroxynaphthalimide methanesulfonate, and

N-hydroxynaphthalimide benzenesulfonate.

Also included are the oxime sulfonates described in U.S. Pat. No. 6,004,724, for example,

(5-(4-toluenesulfonyl)oxyimino-5H-thiophen-2-ylidene)phenylacetonitrile,

(5-(10-camphorsulfonyl)oxyimino-5H-thiophen-2-ylidene)phenylacetonitrile,

(5-n-octanesulfonyloxyimino-5H-thiophen-2-ylidene)phenylacetonitrile,

(5-(4-toluenesulfonyl)oxyimino-5H-thiophen-2-ylidene)(2-methylphenyl)acetonitrile,

(5-(10-camphorsulfonyl)oxyimino-5H-thiophen-2-ylidene)(2-methylphenyl)acetonitrile,

(5-n-octanesulfonyloxyimino-5H-thiophen-2-ylidene)(2-methylphenyl)acetonitrile, etc.

Also included are the oxime sulfonates described in U.S. Pat. No. 6,261,738 and JP-A 2000-314956, for example,

2,2,2-trifluoro-1-phenyl-ethanone oxime-O-methylsulfonate;

2,2,2-trifluoro-1-phenyl-ethanone oxime-O-(10-camphorylsulfonate);

2,2,2-trifluoro-1-phenyl-ethanone oxime-O-(4-methoxyphenylsulfonate);

2,2,2-trifluoro-1-phenyl-ethanone oxime-O-(1-naphthylsulfonate);

2,2,2-trifluoro-1-phenyl-ethanone oxime-O-(2-naphthylsulfonate);

2,2,2-trifluoro-1-phenyl-ethanone oxime-O-(2,4,6-trimethylphenylsulfonate);

2,2,2-trifluoro-1-(4-methylphenyl)-ethanone oxime-O-(10-camphorylsulfonate);

2,2,2-trifluoro-1-(4-methylphenyl)-ethanone oxime-O-(methylsulfonate);

2,2,2-trifluoro-1-(2-methylphenyl)-ethanone oxime-O-(10-camphorylsulfonate);

2,2,2-trifluoro-1-(2,4-dimethylphenyl)-ethanone oxime-O-(10-camphorylsulfonate);

2,2,2-trifluoro-1-(2,4-dimethylphenyl)-ethanone oxime-O-(1-naphthylsulfonate);

2,2,2-trifluoro-1-(2,4-dimethylphenyl)-ethanone oxime-O-(2-naphthylsulfonate);

2,2,2-trifluoro-1-(2,4,6-trimethylphenyl)-ethanone oxime-O-(10-camphorylsulfonate);

2,2,2-trifluoro-1-(2,4,6-trimethylphenyl)-ethanone oxime-O-(1-naphthylsulfonate);

2,2,2-trifluoro-1-(2,4,6-trimethylphenyl)-ethanone oxime-O-(2-naphthylsulfonate);

2,2,2-trifluoro-1-(4-methoxyphenyl)-ethanone oxime-O-methylsulfonate;

2,2,2-trifluoro-1-(4-methylthiophenyl)-ethanone oxime-O-methylsulfonate;

2,2,2-trifluoro-1-(3,4-dimethoxyphenyl)-ethanone oxime-O-methylsulfonate;

2,2,3,3,4,4,4-heptafluoro-1-phenyl-butanone oxime-O-(10-camphorylsulfonate);

2,2,2-trifluoro-1-(phenyl)-ethanone oxime-O-methylsulfonate;

2,2,2-trifluoro-1-(phenyl)-ethanone oxime-O-10-camphoryl-sulfonate;

2,2,2-trifluoro-1-(phenyl)-ethanone oxime-O-(4-methoxyphenyl)sulfonate;

2,2,2-trifluoro-1-(phenyl)-ethanone oxime-O-(1-naphthyl)-sulfonate;

2,2,2-trifluoro-1-(phenyl)-ethanone oxime-O-(2-naphthyl)-sulfonate;

2,2,2-trifluoro-1-(phenyl)-ethanone oxime-O-(2,4,6-trimethylphenyl)sulfonate;

2,2,2-trifluoro-1-(4-methylphenyl)-ethanone oxime-O-(10-camphoryl)sulfonate;

2,2,2-trifluoro-1-(4-methylphenyl)-ethanone oxime-O-methylsulfonate;

2,2,2-trifluoro-1-(2-methylphenyl)-ethanone oxime-O-(10-camphoryl)sulfonate;

2,2,2-trifluoro-1-(2,4-dimethylphenyl)-ethanone oxime-O-(1-naphthyl)sulfonate;

2,2,2-trifluoro-1-(2,4-dimethylphenyl)-ethanone oxime-O-(2-naphthyl)sulfonate;

2,2,2-trifluoro-1-(2,4,6-trimethylphenyl)-ethanone oxime-O-(10-camphoryl)sulfonate;

2,2,2-trifluoro-1-(2,4,6-trimethylphenyl)-ethanone oxime-O-(1-naphthyl)sulfonate;

2,2,2-trifluoro-1-(2,4,6-trimethylphenyl)-ethanone oxime-O-(2-naphthyl)sulfonate;

2,2,2-trifluoro-1-(4-methoxyphenyl)-ethanone oxime-O-methylsulfonate;

2,2,2-trifluoro-1-(4-thiomethylphenyl)-ethanone oxime-O-methylsulfonate;

2,2,2-trifluoro-1-(3,4-dimethoxyphenyl)-ethanone oxime-O-methylsulfonate;

2,2,2-trifluoro-1-(4-methoxyphenyl)-ethanone oxime-O-(4-methylphenyl)sulfonate;

2,2,2-trifluoro-1-(4-methoxyphenyl)-ethanone oxime-O-(4-methoxyphenyl)sulfonate;

2,2,2-trifluoro-1-(4-methoxyphenyl)-ethanone oxime-O-(4-dodecylphenyl)sulfonate;

2,2,2-trifluoro-1-(4-methoxyphenyl)-ethanone oxime-O-octylsulfonate;

2,2,2-trifluoro-1-(4-thiomethylphenyl)-ethanone oxime-O-(4-methoxyphenyl)sulfonate;

2,2,2-trifluoro-1-(4-thiomethylphenyl)-ethanone oxime-O-(4-dodecylphenyl)sulfonate;

2,2,2-trifluoro-1-(4-thiomethylphenyl)-ethanone oxime-O-octylsulfonate;

2,2,2-trifluoro-1-(4-thiomethylphenyl)-ethanone oxime-O-(2-naphthyl)sulfonate;

2,2,2-trifluoro-1-(2-methylphenyl)-ethanone oxime-O-methylsulfonate;

2,2,2-trifluoro-1-(4-methylphenyl)-ethanone oxime-O-phenylsulfonate;

2,2,2-trifluoro-1-(4-chlorophenyl)-ethanone oxime-O-phenylsulfonate;

2,2,3,3,4,4,4-heptafluoro-1-(phenyl)-butanone oxime-O-(10-camphoryl)sulfonate;

2,2,2-trifluoro-1-naphthyl-ethanone oxime-O-methylsulfonate;

2,2,2-trifluoro-2-naphthyl-ethanone oxime-O-methylsulfonate;

2,2,2-trifluoro-1-[4-benzylphenyl]-ethanone oxime-O-methylsulfonate;

2,2,2-trifluoro-1-[4-(phenyl-1,4-dioxa-but-1-yl)phenyl]-ethanone oxime-O-methylsulfonate;

2,2,2-trifluoro-1-naphthyl-ethanone oxime-O-propylsulfonate;

2,2,2-trifluoro-2-naphthyl-ethanone oxime-O-propylsulfonate;

2,2,2-trifluoro-1-[4-benzylphenyl]-ethanone oxime-O-propylsulfonate;

2,2,2-trifluoro-1-[4-methylsulfonylphenyl]-ethanone oxime-O-propylsulfonate;

1,3-bis[1-(4-phenoxyphenyl)-2,2,2-trifluoroethanone oxime-O-sulfonyl]phenyl;

2,2,2-trifluoro-1-[4-methylsulfonyloxyphenyl]-ethanone oxime-O-propylsulfonate;

2,2,2-trifluoro-1-[4-methylcarbonyloxyphenyl]-ethanone oxime-O-propylsulfonate;

2,2,2-trifluoro-1-[6H,7H-5,8-dioxonaphth-2-yl]-ethanone oxime-O-propylsulfonate;

2,2,2-trifluoro-1-[4-methoxycarbonylmethoxyphenyl]-ethanone oxime-O-propylsulfonate;

2,2,2-trifluoro-1-[4-(methoxycarbonyl)-(4-amino-1-oxa-pent-1-yl)-phenyl]-ethanone oxime-O-propylsulfonate;

2,2,2-trifluoro-1-(3,5-dimethyl-4-ethoxyphenyl)-ethanone oxime-O-propylsulfonate;

2,2,2-trifluoro-1-[4-benzyloxyphenyl]-ethanone oxime-O-propylsulfonate;

2,2,2-trifluoro-1-[2-thiophenyl]-ethanone oxime-O-propylsulfonate; and

2,2,2-trifluoro-1-[1-dioxa-thiophen-2-yl)]-ethanone oxime-O-propylsulfonate.

Also included are the oxime sulfonates described in JP-A 9-95479 and JP-A 9-230588 and the references cited therein, for example,

α-(p-toluenesulfonyloxyimino)-phenylacetonitrile,

α-(p-chlorobenzenesulfonyloxyimino)-phenylacetonitrile,

α-(4-nitrobenzenesulfonyloxyimino)-phenylacetonitrile,

α-(4-nitro-2-trifluoromethylbenzenesulfonyloxyimino)-phenylacetonitrile,

α-(benzenesulfonyloxyimino)-4-chlorophenylacetonitrile,

α-(benzenesulfonyloxyimino)-2,4-dichlorophenylacetonitrile,

α-(benzenesulfonyloxyimino)-2,6-dichlorophenylacetonitrile,

α-(benzenesulfonyloxyimino)-4-methoxyphenylacetonitrile,

α-(2-chlorobenzenesulfonyloxyimino)-4-methoxyphenylacetonitrile,

α-(benzenesulfonyloxyimino)-2-thienylacetonitrile,

α-(4-dodecylbenzenesulfonyloxyimino)-phenylacetonitrile,

α-[(4-toluenesulfonyloxyimino)-4-methoxyphenyl]acetonitrile,

α-[(dodecylbenzenesulfonyloxyimino)-4-methoxyphenyl]acetonitrile,

α-(tosyloxyimino)-3-thienylacetonitrile,

α-(methylsulfonyloxyimino)-1-cyclopentenylacetonitrile,

α-(ethylsulfonyloxyimino)-1-cyclopentenylacetonitrile,

α-(isopropylsulfonyloxyimino)-1-cyclopentenylacetonitrile,

α-(n-butylsulfonyloxyimino)-1-cyclopentenylacetonitrile,

α-(ethylsulfonyloxyimino)-1-cyclohexenylacetonitrile,

α-(isopropylsulfonyloxyimino)-1-cyclohexenylacetonitrile, and

α-(n-butylsulfonyloxyimino)-1-cyclohexenylacetonitrile.

Suitable bisoxime sulfonates include those described in JP-A 9-208554, for example,

bis(α-(4-toluenesulfonyloxy)imino)-p-phenylenediacetonitrile,

bis(α-(benzenesulfonyloxy)imino)-p-phenylenediacetonitrile,

bis(α-(methanesulfonyloxy)imino)-p-phenylenediacetonitrile,

bis(α-(butanesulfonyloxy)imino)-p-phenylenediacetonitrile,

bis(α-(10-camphorsulfonyloxy)imino)-p-phenylenediacetonitrile,

bis(α-(4-toluenesulfonyloxy)imino)-p-phenylenediacetonitrile,

bis(α-(trifluoromethanesulfonyloxy)imino)-p-phenylenediacetonitrile,

bis(α-(4-methoxybenzenesulfonyloxy)imino)-p-phenylenediacetonitrile,

bis(α-(4-toluenesulfonyloxy)imino)-m-phenylenediacetonitrile,

bis(α-(benzenesulfonyloxy)imino)-m-phenylenediacetonitrile,

bis(α-(methanesulfonyloxy)imino)-m-phenylenediacetonitrile,

bis(α-(butanesulfonyloxy)imino)-m-phenylenediacetonitrile,

bis(α-(10-camphorsulfonyloxy)imino)-m-phenylenediacetonitrile,

bis(α-(4-toluenesulfonyloxy)imino)-m-phenylenediacetonitrile,

bis(α-(trifluoromethanesulfonyloxy)imino)-m-phenylenediacetonitrile,

bis(α-( 4-methoxybenzenesulfonyloxy)imino)-m-phenylenediacetonitrile, etc.

These photoacid generators may be used singly or in combinations of two or more thereof. Onium salts are effective for improving rectangularity, while diazomethane derivatives and glyoxime derivatives are effective for reducing standing waves. The combination of an onium salt with a diazomethane or a glyoxime derivative allows for fine adjustment of the profile.

The photoacid generator is added in an amount of 0.1 to 50 parts, and especially 0.5 to 40 parts by weight, per 100 parts by weight of the base resin (all parts are by weight, hereinafter). Less than 0.1 part of the photoacid generator may generate a less amount of acid upon exposure, sometimes leading to a poor sensitivity and resolution whereas more than 50 parts of the photoacid generator may adversely affect the transmittance and resolution of resist.

Organic Solvent

The organic solvent used herein may be any organic solvent in which the base resin, photoacid generator, and other components are soluble. Illustrative, non-limiting, examples of the organic solvent include ketones such as cyclohexanone and methyl-2-n-amylketone; alcohols such as 3-methoxybutanol, 3-methyl-3-methoxybutanol, 1-methoxy-2-propanol, and 1-ethoxy-2-propanol; ethers such as propylene glycol monomethyl ether, ethylene glycol monomethyl ether, propylene glycol monoethyl ether, ethylene glycol monoethyl ether, propylene glycol dimethyl ether, and diethylene glycol dimethyl ether; esters such as propylene glycol monomethyl ether acetate, propylene glycol monoethyl ether acetate, ethyl lactate, ethyl pyruvate, butyl acetate, methyl 3-methoxypropionate, ethyl 3-ethoxypropionate, tert-butyl acetate, tert-butyl propionate, and propylene glycol mono-tert-butyl ether acetate; and lactones such as y-butyrolactone. These solvents may be used alone or in combinations of two or more thereof. Of the above organic solvents, it is recommended to use diethylene glycol dimethyl ether and 1-ethoxy-2-propanol in which the photoacid generator is most soluble, propylene glycol monomethyl ether acetate, or a mixture thereof.

An appropriate amount of the organic solvent used is about 200 to 1,000 parts, especially about 400 to 800 parts by weight per 100 parts by weight of the base resin.

Dissolution Inhibitor

To the resist composition, a dissolution inhibitor may be added. The dissolution inhibitor is a compound having on the molecule at least two phenolic hydroxyl groups, in which an average of from 0 to 100 mol % of all the hydrogen atoms on the phenolic hydroxyl groups are replaced with acid labile groups or a compound having on the molecule at least one carboxyl group, in which an average of 50 to 100 mol % of all the hydrogen atoms on the carboxyl groups are replaced with acid labile groups, both the compounds having an average molecular weight within a range of 100 to 1,000, and preferably 150 to 800.

The degree of substitution of the hydrogen atoms on the phenolic hydroxyl groups with acid labile groups is on average at least 0 mol %, and preferably at least 30 mol %, of all the phenolic hydroxyl groups. The upper limit is 100 mol %, and preferably 80 mol %. The degree of substitution of the hydrogen atoms on the carboxyl groups with acid labile groups is on average at least 50 mol %, and preferably at least 70 mol %, of all the carboxyl groups, with the upper limit being 100 mol %.

Preferable examples of such compounds having two or more phenolic hydroxyl groups or compounds having at least one carboxyl group include those of formulas (D1) to (D14) below.

In these formulas, R²⁰¹ and R²⁰² are each hydrogen or a straight or branched alkyl or alkenyl of 1 to 8 carbon atoms; R²⁰³ is hydrogen, a straight or branched alkyl or alkenyl of 1 to 8 carbon atoms, or —(R²⁰⁷)_(h)—COOH; R²⁰⁴ is —(CH₂)_(i)— (where i=2 to 10), an arylene of 6 to 10 carbon atoms, carbonyl, sulfonyl, an oxygen atom, or a sulfur atom; R²⁰⁵ is an alkylene of 1 to 10 carbon atoms, an arylene of 6 to 10 carbon atoms, carbonyl, sulfonyl, an oxygen atom, or a sulfur atom; R²⁰⁶ is hydrogen, a straight or branched alkyl or alkenyl of 1 to 8 carbon atoms, or a hydroxyl-substituted phenyl or naphthyl; R²⁰⁷ is a straight or branched alkylene of 1 to 10 carbon atoms; R²⁰⁸ is hydrogen or hydroxyl; the letter j is an integer from 0 to 5; u and h are each 0 or 1; s, t, s′, t′, s″, and t″ are each numbers which satisfy s+t=8, s′+t′=5, and s″+t″=4, and are such that each phenyl skeleton has at least one hydroxyl group; and α is a number such that the compounds of formula (D8) or (D9) have a molecular weight of from 100 to 1,000.

In the above formulas, suitable examples of R²⁰¹ and R²⁰² include hydrogen, methyl, ethyl, butyl, propyl, ethynyl, and cyclohexyl; suitable examples of R²⁰³ include the same groups as for R²⁰¹ and R²⁰², as well as —COOH and —CH₂COOH; suitable examples of R²⁰⁴ include ethylene, phenylene, carbonyl, sulfonyl, oxygen, and sulfur; suitable examples of R²⁰⁵ include methylene as well as the same groups as for R²⁰⁴; and suitable examples of R²⁰⁶ include hydrogen, methyl, ethyl, butyl, propyl, ethynyl, cyclohexyl, and hydroxyl-substituted phenyl or naphthyl.

Exemplary acid labile groups on the dissolution inhibitor include a variety of such groups, and typically groups of the following general formulae (L1) to (L4), tertiary alkyl groups of 4 to 20 carbon atoms, trialkylsilyl groups in which each of the alkyls has 1 to 6 carbon atoms, and oxoalkyl groups of 4 to 20 carbon atoms.

In these formulas, R^(L01) and R^(L02) are each hydrogen or a straight, branched or cyclic alkyl having 1 to 18 carbon atoms; and R^(L03) is a monovalent hydrocarbon group of 1 to 18 carbon atoms which may contain a heteroatom (e.g., oxygen). A pair of R^(L01) and R^(L02), a pair of R^(L01) and R^(L03) or a pair of R^(L02) and R^(L03) may together form a ring, with the proviso that R^(L01), R^(L02), and R^(L03) are each a straight or branched alkylene of 1 to 18 carbon atoms when they form a ring. R^(L04) is a tertiary alkyl group of 4 to 20 carbon atoms, a trialkysilyl group in which each of the alkyls has 1 to 6 carbon atoms, an oxoalkyl group of 4 to 20 carbon atoms, or a group of the formula (L1). R^(L05) is a monovalent hydrocarbon groups of 1 to 8 carbon atoms which may contain a hetero atom or a substituted or unsubstituted aryl group of 6 to 20 carbon atoms. R^(L06) is a monovalent hydrocarbon groups of 1 to 8 carbon atoms which may contain a hetero atom or a substituted or unsubstituted aryl group of 6 to 20 carbon atoms. R^(L07) to R^(L16) independently represent hydrogen or monovalent hydrocarbon groups of 1 to 15 carbon atoms which may contain a hetero atom. Alternatively, R^(L07) to R^(L16), taken together, may form a ring. Each of R^(L07) to R^(L16) represents a divalent C₁-C₁₅ hydrocarbon group which may contain a hetero atom, when they form a ring. Two of R^(L07) to R^(L16) which are attached to adjoining carbon atoms may bond together directly to form a double bond. Letter y is an integer of 0 to 6. Letter m is equal to 0 or 1, n is equal to 0, 1, 2 or 3, and 2m+n is equal to 2 or 3. Illustrative examples of these groups are as previously exemplified.

The dissolution inhibitor may be formulated in an amount of 0 to 50 parts, preferably 0 to 40 parts, and more preferably 0 to 30 parts, per 100 parts of the base resin, and may be used singly or as a mixture of two or more thereof. The use of more than 50 parts would lead to slimming of the patterned film, and thus a decline in resolution.

The dissolution inhibitor can be synthesized by introducing acid labile groups into a compound having phenolic hydroxyl or carboxyl groups in accordance with an organic chemical formulation.

Basic Compound

In the resist composition of the invention, a basic compound may be blended. A suitable basic compound used herein is a compound capable of suppressing the rate of diffusion when the acid generated by the photoacid generator diffuses within the resist film. The inclusion of this type of basic compound holds down the rate of acid diffusion within the resist film, resulting in better resolution. In addition, it suppresses changes in sensitivity following exposure, thus reducing substrate and environment dependence, as well as improving the exposure latitude and the pattern profile.

Examples of basic compounds include primary, secondary, and tertiary aliphatic amines, mixed amines, aromatic amines, heterocyclic amines, carboxyl group-bearing nitrogenous compounds, sulfonyl group-bearing nitrogenous compounds, hydroxyl group-bearing nitrogenous compounds, hydroxyphenyl group-bearing nitrogenous compounds, alcoholic nitrogenous compounds, amide derivatives, and imide derivatives.

Examples of suitable primary aliphatic amines include ammonia, methylamine, ethylamine, n-propylamine, isopropylamine, n-butylamine, isobutylamine, sec-butylamine, tert-butylamine, pentylamine, tert-amylamine, cyclopentylamine, hexylamine, cyclohexylamine, heptylamine, octylamine, nonylamine, decylamine, dodecylamine, cetylamine, methylenediamine, ethylenediamine, and tetraethylenepentamine. Examples of suitable secondary aliphatic amines include dimethylamine, diethylamine, di-n-propylamine, diisopropylamine, di-n-butylamine, diisobutylamine, di-sec-butylamine, dipentylamine, dicyclopentylamine, dihexylamine, dicyclohexylamine, diheptylamine, dioctylamine, dinonylamine, didecylamine, didodecylamine, dicetylamine, N, N-dimethylmethylenediamine, N, N-dimethylethylenediamine, and N,N-dimethyltetraethylenepentamine. Examples of suitable tertiary aliphatic amines include trimethylamine, triethylamine, tri-n-propylamine, triisopropylamine, tri-n-butylamine, triisobutylamine, tri-sec-butylamine, tripentylamine, tricyclopentylamine, trihexylamine, tricyclohexylamine, triheptylamine, trioctylamine, trinonylamine, tridecylamine, tridodecylamine, tricetylamine, N,N,N′,N′-tetramethylmethylenediamine, N,N,N′,N′-tetramethylethylenediamine, and N,N,N′,N′-tetramethyltetraethylenepentamine.

Examples of suitable mixed amines include dimethylethylamine, methylethylpropylamine, benzylamine, phenethylamine, and benzyldimethylamine. Examples of suitable aromatic and heterocyclic amines include aniline derivatives (e.g., aniline, N-methylaniline, N-ethylaniline, N-propylaniline, N,N-dimethylaniline, 2-methylaniline, 3-methylaniline, 4-methylaniline, ethylaniline, propylaniline, trimethylaniline, 2-nitroaniline, 3-nitroaniline, 4-nitroaniline, 2,4-dinitroaniline, 2,6-dinitroaniline, 3,5-dinitroaniline, and N,N-dimethyltoluidine), diphenyl(p-tolyl)amine, methyldiphenylamine, triphenylamine, phenylenediamine, naphthylamine, diaminonaphthalene, pyrrole derivatives (e.g., pyrrole, 2H-pyrrole, 1-methylpyrrole, 2,4-dimethylpyrrole, 2,5-dimethylpyrrole, and N-methylpyrrole), oxazole derivatives (e.g., oxazole and isooxazole), thiazole derivatives (e.g., thiazole and isothiazole), imidazole derivatives (e.g., imidazole, 4-methylimidazole, and 4-methyl-2-phenylimidazole), pyrazole derivatives, furazan derivatives, pyrroline derivatives (e.g., pyrroline and 2-methyl-1-pyrroline), pyrrolidine derivatives (e.g., pyrrolidine, N-methylpyrrolidine, pyrrolidinone, and N-methylpyrrolidone), imidazoline derivatives, imidazolidine derivatives, pyridine derivatives (e.g., pyridine, methylpyridine, ethylpyridine, propylpyridine, butylpyridine, 4-(1-butylpentyl)pyridine, dimethylpyridine, trimethylpyridine, triethylpyridine, phenylpyridine, 3-methyl-2-phenylpyridine, 4-tert-butylpyridine, diphenylpyridine, benzylpyridine, methoxypyridine, butoxypyridine, dimethoxypyridine, 1-methyl-2-pyridine, 4-pyrrolidinopyridine, 1-methyl-4-phenylpyridine, 2-(1-ethylpropyl)pyridine, aminopyridine, and dimethylaminopyridine), pyridazine derivatives, pyrimidine derivatives, pyrazine derivatives, pyrazoline derivatives, pyrazolidine derivatives, piperidine derivatives, piperazine derivatives, morpholine derivatives, indole derivatives, isoindole derivatives, 1H-indazole derivatives, indoline derivatives, quinoline derivatives (e.g., quinoline and 3-quinolinecarbonitrile), isoquinoline derivatives, cinnoline derivatives, quinazoline derivatives, quinoxaline derivatives, phthalazine derivatives, purine derivatives, pteridine derivatives, carbazole derivatives, phenanthridine derivatives, acridine derivatives, phenazine derivatives, 1,10-phenanthroline derivatives, adenine derivatives, adenosine derivatives, guanine derivatives, guanosine derivatives, uracil derivatives, and uridine derivatives.

Examples of suitable carboxyl group-bearing nitrogenous compounds include aminobenzoic acid, indolecarboxylic acid, and amino acid derivatives (e.g. nicotinic acid, alanine, alginine, aspartic acid, glutamic acid, glycine, histidine, isoleucine, glycylleucine, leucine, methionine, phenylalanine, threonine, lysine, 3-aminopyrazine-2-carboxylic acid, and methoxyalanine). Examples of suitable sulfonyl group-bearing nitrogenous compounds include 3-pyridinesulfonic acid and pyridinium p-toluenesulfonate. Examples of suitable hydroxyl group-bearing nitrogenous compounds, hydroxyphenyl group-bearing nitrogenous compounds, and alcoholic nitrogenous compounds include 2-hydroxypyridine, aminocresol, 2,4-quinolinediol, 3-indolemethanol hydrate, monoethanolamine, diethanolamine, triethanolamine, N-ethyldiethanolamine, N,N-diethylethanolamine, triisopropanolamine, 2,2′-iminodiethanol, 2-aminoethanol, 3-amino-1-propanol, 4-amino-1-butanol, 4-(2-hydroxyethyl)morpholine, 2-(2-hydroxyethyl)pyridine, 1-(2-hydroxyethyl)piperazine, 1-[2-(2-hydroxyethoxy)ethyl]piperazine, piperidine ethanol, 1-(2-hydroxyethyl)pyrrolidine, 1-(2-hydroxyethyl)-2-pyrrolidinone, 3-piperidino-1,2-propanediol, 3-pyrrolidino-1,2-propanediol, 8-hydroxyjulolidine, 3-quinuclidinol, 3-tropanol, 1-methyl-2-pyrrolidine ethanol, 1-aziridine ethanol, N-(2-hydroxyethyl)phthalimide, and N-(2-hydroxyethyl)isonicotinamide. Examples of suitable amide derivatives include formamide, N-methylformamide, N,N-dimethylformamide, acetamide, N-methylacetamide, N,N-dimethylacetamide, propionamide, and benzamide. Suitable imide derivatives include phthalimide, succinimide, and maleimide.

In addition, basic compounds of the following general formula (B)-1 may also be included alone or in admixture. N(X)_(n)(Y)_(3−n)  (B)-1

In the formula, n is equal to 1, 2 or 3; side chain Y is independently hydrogen or a straight, branched or cyclic alkyl group of 1 to 20 carbon atoms which may contain an ether or hydroxyl group; and side chain X is independently selected from groups of the following general formulas (X)-1to (X)-3, and two or three X's may bond together to form a ring.

In the formulas, R³⁰⁰, R³⁰² and R³⁰⁵ are independently straight or branched alkylene groups of 1 to 4 carbon atoms; R³⁰¹ and R³⁰⁴ are independently hydrogen, straight, branched or cyclic alkyl groups of 1 to 20 carbon atoms, which may contain at least one hydroxyl, ether, ester group or lactone ring; R³⁰³ is a single bond or a straight or branched alkylene group of 1 to 4 carbon atoms; and R³⁰⁶ is a straight, branched or cyclic alkyl group of 1 to 20 carbon atoms, which may contain at least one hydroxyl, ether, ester group or lactone ring.

Illustrative examples of the basic compounds of formula (B)-1 include tris(2-methoxymethoxyethyl)amine,

tris{2-(2-methoxyethoxy)ethyl}amine,

tris{2-(2-methoxyethoxymethoxy)ethyl}amine,

tris{2-(1-methoxyethoxy)ethyl}amine,

tris{2-(1-ethoxyethoxy)ethyl}amine,

tris{2-(1-ethoxypropoxy)ethyl}amine,

tris[2-{2-(2-hydroxyethoxy)ethoxy}ethyl]amine,

4,7,13,16,21,24-hexaoxa-1,10-diazabicyclo[8.8.8]hexacosane,

4,7,13,18-tetraoxa-1,10-diazabicyclo[8.5.5]eicosane,

1,4,10,13-tetraoxa-7,16-diazabicyclooctadecane,

1-aza-12-crown-4, 1-aza-15-crown-5, 1-aza-18-crown-6,

tris(2-formyloxyethyl)amine, tris(2-acetoxyethyl)amine,

tris(2-propionyloxyethyl)amine, tris(2-butyryloxyethyl)amine,

tris(2-isobutyryloxyethyl)amine, tris(2-valeryloxyethyl)amine,

tris(2-pivaloyloxyethyl)amine,

N,N-bis(2-acetoxyethyl)-2-(acetoxyacetoxy)ethylamine,

tris(2-methoxycarbonyloxyethyl)amine,

tris(2-tert-butoxycarbonyloxyethyl)amine,

tris[2-(2-oxopropoxy)ethyl]amine,

tris[2-(methoxycarbonylmethyl)oxyethyl]amine,

tris[2-(tert-butoxycarbonylmethyloxy)ethyl]amine,

tris[2-(cyclohexyloxycarbonylmethyloxy)ethyl]amine,

tris(2-methoxycarbonylethyl)amine,

tris(2-ethoxycarbonylethyl)amine,

N,N-bis(2-hydroxyethyl)-2-(methoxycarbonyl)ethylamine,

N,N-bis(2-acetoxyethyl)-2-(methoxycarbonyl)ethylamine,

N,N-bis(2-hydroxyethyl)-2-(ethoxycarbonyl)ethylamine,

N,N-bis(2-acetoxyethyl)-2-(ethoxycarbonyl)ethylamine,

N,N-bis(2-hydroxyethyl)-2-(2-methoxyethoxycarbonyl)ethylamine,

N,N-bis(2-acetoxyethyl)-2-(2-methoxyethoxycarbonyl)ethylamine,

N,N-bis(2-hydroxyethyl)-2-(2-hydroxyethoxycarbonyl)ethylamine,

N,N-bis(2-acetoxyethyl)-2-(2-acetoxyethoxycarbonyl)ethylamine,

N,N-bis(2-hydroxyethyl)-2-[(methoxycarbonyl)methoxycarbonyl]ethylamine,

N,N-bis(2-acetoxyethyl)-2-[(methoxycarbonyl)methoxycarbonyl]ethylamine,

N,N-bis(2-hydroxyethyl)-2-(2-oxopropoxycarbonyl)ethylamine,

N,N-bis(2-acetoxyethyl)-2-(2-oxopropoxycarbonyl)ethylamine,

N,N-bis(2-hydroxyethyl)-2-(tetrahydrofurfuryloxycarbonyl)ethylamine,

N,N-bis(2-acetoxyethyl)-2-(tetrahydrofurfuryloxycarbonyl)ethylamine,

N,N-bis(2-hydroxyethyl)-2-[(2-oxotetrahydrofuran-3-yl)oxycarbonyl]ethylamine,

N,N-bis(2-acetoxyethyl)-2-[(2-oxotetrahydrofuran-3-yl)oxycarbonyl]ethylamine,

N,N-bis(2-hydroxyethyl)-2-(4-hydroxybutoxycarbonyl)ethylamine,

N,N-bis(2-formyloxyethyl)-2-(4-formyloxybutoxycarbonyl)ethylamine,

N,N-bis(2-formyloxyethyl)-2-(2-formyloxyethoxycarbonyl)ethylamine,

N,N-bis(2-methoxyethyl)-2-(methoxycarbonyl)ethylamine,

N-(2-hydroxyethyl)-bis[2-(methoxycarbonyl)ethyl]amine,

N-(2-acetoxyethyl)-bis[2-(methoxycarbonyl)ethyl]amine,

N-(2-hydroxyethyl)-bis[2-(ethoxycarbonyl)ethyl]amine,

N-(2-acetoxyethyl)-bis[2-(ethoxycarbonyl)ethyl]amine,

N-(3-hydroxy-1-propyl)-bis[2-(methoxycarbonyl)ethyl]amine,

N-(3-acetoxy-1-propyl)-bis[2-(methoxycarbonyl)ethyl]amine,

N-(2-methoxyethyl)-bis[2-(methoxycarbonyl)ethyl]amine,

N-butyl-bis[2-(methoxycarbonyl)ethyl]amine,

N-butyl-bis[2-(2-methoxyethoxycarbonyl)ethyl]amine,

N-methyl-bis(2-acetoxyethyl)amine,

N-ethyl-bis(2-acetoxyethyl)amine,

N-methyl-bis(2-pivaloyloxyethyl)amine,

N-ethyl-bis[2-(methoxycarbonyloxy)ethyl]amine,

N-ethyl-bis[2-(tert-butoxycarbonyloxy)ethyl]amine,

tris(methoxycarbonylmethyl)amine,

tris(ethoxycarbonylmethyl)amine,

N-butyl-bis(methoxycarbonylmethyl)amine,

N-hexyl-bis(methoxycarbonylmethyl)amine, and

β-(diethylamino)-δ-valerolactone.

Also useful are one or more of cyclic structure-bearing basic compounds having the following general formula (B)-2.

Herein X is as defined above, and R³⁰⁷ is a straight or branched alkylene group of 2 to 20 carbon atoms which may contain one or more carbonyl, ether, ester or sulfide groups.

Illustrative examples of the cyclic structure-bearing basic compounds having formula (B)-2 include

1-[2-(methoxymethoxy)ethyl]pyrrolidine,

1-[2-(methoxymethoxy)ethyl]piperidine,

4-[2-(methoxymethoxy)ethyl]morpholine,

1-[2-[(2-methoxyethoxy)methoxy]ethyl]pyrrolidine,

1-[2-[(2-methoxyethoxy)methoxy]ethyl]piperidine,

4-[2-[(2-methoxyethoxy)methoxy]ethyl]morpholine,

2-(1-pyrrolidinyl)ethyl acetate, 2-piperidinoethyl acetate,

2-morpholinoethyl acetate, 2-(1-pyrrolidinyl)ethyl formate,

2-piperidinoethyl propionate,

2-morpholinoethyl acetoxyacetate,

2-(1-pyrrolidinyl)ethyl methoxyacetate,

4-[2-(methoxycarbonyloxy)ethyl]morpholine,

1-[2-(t-butoxycarbonyloxy)ethyl]piperidine,

4-[2-(2-methoxyethoxycarbonyloxy)ethyl]morpholine,

methyl 3-(1-pyrrolidinyl)propionate,

methyl 3-piperidinopropionate,

methyl 3-morpholinopropionate,

methyl 3-(thiomorpholino)propionate,

methyl 2-methyl-3-(1-pyrrolidinyl)propionate,

ethyl 3-morpholinopropionate,

methoxycarbonylmethyl 3-piperidinopropionate,

2-hydroxyethyl 3-(1-pyrrolidinyl)propionate,

2-acetoxyethyl 3-morpholinopropionate,

2-oxotetrahydrofuran-3-yl 3-(1-pyrrolidinyl)propionate,

tetrahydrofurfuryl 3-morpholinopropionate,

glycidyl 3-piperidinopropionate,

2-methoxyethyl 3-morpholinopropionate,

2-(2-methoxyethoxy)ethyl 3-(1-pyrrolidinyl)propionate,

butyl 3-morpholinopropionate,

cyclohexyl 3-piperidinopropionate,

α-(1-pyrrolidinyl)methyl-y-butyrolactone,

β-piperidino-γ-butyrolactone, β-morpholino-δ-valerolactone,

methyl 1-pyrrolidinylacetate, methyl piperidinoacetate,

methyl morpholinoacetate, methyl thiomorpholinoacetate,

ethyl 1-pyrrolidinylacetate, and

2-methoxyethyl morpholinoacetate.

Also, one or more of cyano-bearing basic compounds having the following general formulae (B)-3 to (B)-6 may be blended.

Herein, X, R³⁰⁷ and n are as defined above, and R³⁰⁸ and R³⁰⁹ are each independently a straight or branched alkylene group of 1 to 4 carbon atoms.

Illustrative examples of the cyano-bearing basic compounds having formulae (B)-3 to (B)-6 include

3-(diethylamino)propiononitrile,

N,N-bis(2-hydroxyethyl)-3-aminopropiononitrile,

N,N-bis(2-acetoxyethyl)-3-aminopropiononitrile,

N,N-bis(2-formyloxyethyl)-3-aminopropiononitrile,

N,N-bis(2-methoxyethyl)-3-aminopropiononitrile,

N,N-bis[2-(methoxymethoxy)ethyl]-3-aminopropiononitrile,

methyl N-(2-cyanoethyl)-N-(2-methoxyethyl)-3-aminopropionate,

methyl N-(2-cyanoethyl)-N-(2-hydroxyethyl)-3-aminopropionate,

methyl N-(2-acetoxyethyl)-N-(2-cyanoethyl)-3-aminopropionate,

N-(2-cyanoethyl)-N-ethyl-3-aminopropiononitrile,

N-(2-cyanoethyl)-N-(2-hydroxyethyl)-3-aminopropiononitrile,

N-(2-acetoxyethyl)-N-(2-cyanoethyl)-3-aminopropiononitrile,

N-(2-cyanoethyl)-N-(2-formyloxyethyl)-3-aminopropiononitrile,

N-(2-cyanoethyl)-N-(2-methoxyethyl)-3-aminopropiononitrile,

N-(2-cyanoethyl)-N-[2-(methoxymethoxy)ethyl]-3-aminopropiononitrile,

N-(2-cyanoethyl)-N-(3-hydroxy-1-propyl)-3-aminopropiononitrile,

N-(3-acetoxy-1-propyl)-N-(2-cyanoethyl)-3-aminopropiononitrile,

N-(2-cyanoethyl)-N-(3-formyloxy-1-propyl)-3-aminopropiononitrile,

N-(2-cyanoethyl)-N-tetrahydrofurfuryl-3-aminopropiononitrile,

N,N-bis(2-cyanoethyl)-3-aminopropiononitrile, diethylaminoacetonitrile,

N,N-bis(2-hydroxyethyl)aminoacetonitrile,

N,N-bis(2-acetoxyethyl)aminoacetonitrile,

N,N-bis(2-formyloxyethyl)aminoacetonitrile,

N,N-bis(2-methoxyethyl)aminoacetonitrile,

N,N-bis[2-(methoxymethoxy)ethyl]aminoacetonitrile,

methyl N-cyanomethyl-N-(2-methoxyethyl)-3-aminopropionate,

methyl N-cyanomethyl-N-(2-hydroxyethyl)-3-aminopropionate,

methyl N-(2-acetoxyethyl)-N-cyanomethyl-3-aminopropionate,

N-cyanomethyl-N-(2-hydroxyethyl)aminoacetonitrile,

N-(2-acetoxyethyl)-N-(cyanomethyl)aminoacetonitrile,

N-cyanomethyl-N-(2-formyloxyethyl)aminoacetonitrile,

N-cyanomethyl-N-(2-methoxyethyl)aminoacetonitrile,

N-cyanomethyl-N-[2-(methoxymethoxy)ethyl]aminoacetonitrile,

N-cyanomethyl-N-(3-hydroxy-1-propyl)aminoacetonitrile,

N-(3-acetoxy-1-propyl)-N-(cyanomethyl)aminoacetonitrile,

N-cyanomethyl-N-(3-formyloxy-1-propyl)aminoacetonitrile,

N,N-bis(cyanomethyl)aminoacetonitrile,

1-pyrrolidinepropiononitrile, 1-piperidinepropiononitrile,

4-morpholinepropiononitrile, 1-pyrrolidineacetonitrile,

1-piperidineacetonitrile, 4-morpholineacetonitrile,

cyanomethyl 3-diethylaminopropionate,

cyanomethyl N,N-bis(2-hydroxyethyl)-3-aminopropionate,

cyanomethyl N,N-bis(2-acetoxyethyl)-3-aminopropionate,

cyanomethyl N,N-bis(2-formyloxyethyl)-3-aminopropionate,

cyanomethyl N,N-bis(2-methoxyethyl)-3-aminopropionate,

cyanomethyl N,N-bis[2-(methoxymethoxy)ethyl]-3-aminopropionate,

2-cyanoethyl 3-diethylaminopropionate,

2-cyanoethyl N,N-bis(2-hydroxyethyl)-3-aminopropionate,

2-cyanoethyl N,N-bis(2-acetoxyethyl)-3-aminopropionate,

2-cyanoethyl N,N-bis(2-formyloxyethyl)-3-aminopropionate,

2-cyanoethyl N,N-bis(2-methoxyethyl)-3-aminopropionate,

2-cyanoethyl N,N-bis[2-(methoxymethoxy)ethyl]-3-aminopropionate,

cyanomethyl 1-pyrrolidinepropionate,

cyanomethyl 1-piperidinepropionate,

cyanomethyl 4-morpholinepropionate,

2-cyanoethyl 1-pyrrolidinepropionate,

2-cyanoethyl 1-piperidinepropionate, and

2-cyanoethyl 4-morpholinepropionate.

The basic compounds may be used alone or in admixture of two or more. The basic compound is preferably formulated in an amount of 0.001 to 2 parts, and especially 0.01 to 1 part by weight, per 100 parts by weight of the entire base resin. Less than 0.001 part of the basic compound achieves no or little addition effect whereas more than 2 parts would result in too low a sensitivity.

Other Components

In the resist composition, a compound bearing a ≡—C—COOH group in a molecule may be blended. Exemplary, non-limiting compounds bearing a ≡—C—COOH group include one or more compounds selected from Groups I and II below. Including this compound improves the PED stability of the resist and ameliorates edge roughness on nitride film substrates.

Group I:

Compounds in which some or all of the hydrogen atoms on the phenolic hydroxyl groups of the compounds of general formulas (A1) to (A10) below have been replaced with —R⁴⁰¹—COOH (wherein R⁴⁰¹ is a straight or branched alkylene of 1 to 10 carbon atoms), and in which the molar ratio C/(C+D) of phenolic hydroxyl groups (C) to ≡—C—COOH groups (D) in the molecule is from 0.1 to 1.0.

In these formulas, R⁴⁰⁸ is hydrogen or methyl; R⁴⁰² and R⁴⁰³ are each hydrogen or a straight or branched alkyl or alkenyl of 1 to 8 carbon atoms; R⁴⁰⁴ is hydrogen, a straight or branched alkyl or alkenyl of 1 to 8 carbon atoms, or a —(R⁴⁰⁹)_(h)—COOR′ group (R′ being hydrogen or —R⁴⁰⁹—COOH); R⁴⁰⁵ is —(CH₂)_(i)— (wherein i is 2 to 10), an arylene of 6 to 10 carbon atoms, carbonyl, sulfonyl, an oxygen atom, or a sulfur atom; R⁴⁰⁶ is an alkylene of 1 to 10 carbon atoms, an arylene of 6 to 10 carbon atoms, carbonyl, sulfonyl, an oxygen atom, or a sulfur atom; R⁴⁰⁷ is hydrogen, a straight or branched alkyl or alkenyl of 1 to 8 carbon atoms, or a hydroxyl-substituted phenyl or naphthyl; R⁴⁰⁹ is a straight or branched alkylene of 1 to 10 carbon atoms; R⁴¹⁰ is hydrogen, a straight or branched alkyl or alkenyl of 1 to 8 carbon atoms, or a —R⁴¹¹—COOH group; R⁴¹¹ is a straight or branched alkylene of 1 to 10 carbon atoms; the letter j is an integer from 0 to 5; u and h are each 0 or 1; s1, t1, s2, t2, s3, t3, s4, and t4 are each numbers which satisfy s1+t1=8, s2+t2=5, s3+t3=4, and s4+t4=6, and are such that each phenyl skeleton has at least one hydroxyl group; κ is a number such that the compound of formula (A6) may have a weight average molecular weight of 1,000 to 5,000; and λ is a number such that the compound of formula (A7) may have a weight average molecular weight of 1,000 to 10,000.

Group II:

Compounds of general formulas (A11) to (A15) below.

In these formulas, R⁴⁰², R⁴⁰³, and R⁴¹¹ are as defined above; R⁴¹² is hydrogen or hydroxyl; s5 and t5 are numbers which satisfy s5>0, t5>0, and s5+t5=5; and h′ is equal to 0 or 1.

Illustrative, non-limiting examples of the compound bearing a □—C—COOH group include compounds of the general formulas AI-1 to AI-14 and AII-1 to AII-10 below.

In the above formulas, R″ is hydrogen or a CH₂COOH group such that the CH₂COOH group accounts for 10 to 100 mol % of R″ in each compound, κ and λ are as defined above.

The compound bearing a ≡—C—COOH group within the molecule may be used singly or as combinations of two or more thereof.

The compound bearing a ≡—C—COOH group within the molecule is added in an amount ranging from 0 to 5 parts, preferably 0.1 to 5 parts, more preferably 0.1 to 3 parts, further preferably 0.1 to 2 parts, per 100 parts of the base resin. More than 5 parts of the compound can reduce the resolution of the resist composition.

The resist composition of the invention may additionally include an acetylene alcohol derivative for the purpose of enhancing the shelf stability. Preferred acetylene alcohol derivatives are those having the general formula (S1) or (S2) below.

In the formulas, R⁵⁰¹, R⁵⁰², R⁵⁰³, R⁵⁰⁴, and R⁵⁰⁵ are each hydrogen or a straight, branched, or cyclic alkyl of 1 to 8 carbon atoms; and X and Y are each 0 or a positive number, satisfying 0≦X≦30, 0≦Y≦30, and 0≦X+Y≦40.

Preferable examples of the acetylene alcohol derivative include Surfynol 61, Surfynol 82, Surfynol 104, Surfynol 104E, Surfynol 104H, Surfynol 104A, Surfynol TG, Surfynol PC, Surfynol 440, Surfynol 465, and Surfynol 485 from Air Products and Chemicals Inc., and Surfynol E1004 from Nisshin Chemical Industry Co. Ltd.

The acetylene alcohol derivative is preferably added in an amount of 0.01 to 2% by weight, and more preferably 0.02 to 1% by weight, per 100% by weight of the resist composition. Less than 0.01% by weight would be ineffective for improving coating characteristics and shelf stability, whereas more than 2% by weight would result in a resist having a low resolution.

The resist composition of the invention may include optional ingredients, for example, a surfactant which is commonly used for improving the coating characteristics. Optional ingredients may be added in conventional amounts so long as this does not compromise the objects of the invention.

Nonionic surfactants are preferred, examples of which include perfluoroalkylpolyoxyethylene ethanols, fluorinated alkyl esters, perfluoroalkylamine oxides, perfluoroalkyl EO-addition products, and fluorinated organosiloxane compounds. Useful surfactants are commercially available under the trade names Florade FC-430 and FC-431 from Sumitomo 3M, Ltd., Surflon S-141, S-145, KH-10, KH-20, KH-30 and KH-40 from Asahi Glass Co., Ltd., Unidyne DS-401, DS-403 and DS-451 from Daikin Industry Co., Ltd., Megaface F-8151 from Dai-Nippon Ink & Chemicals, Inc., and X-70-092 and X-70-093 from Shin-Etsu Chemical Co., Ltd. Preferred surfactants are Florade FC-430 from Sumitomo 3M, Ltd., KH-20 and KH-30 from Asahi Glass Co., Ltd., and X-70-093 from Shin-Etsu Chemical Co., Ltd.

Pattern formation using the resist composition of the invention may be carried out by a known lithographic technique. For example, the resist composition is applied onto a substrate such as a silicon wafer by spin coating or the like to form a resist film having a thickness of 0.2 to 2.0 μm, which is then pre-baked on a hot plate at 60 to 150° C. for 1 to 10 minutes, and preferably at 80 to 130° C. for 1 to 5 minutes. A patterning mask having the desired pattern is then placed over the resist film, and the film exposed through the mask to an electron beam or to high-energy radiation such as deep-UV rays, an excimer laser, or x-rays in a dose of about 1 to 200 mJ/cm², and preferably about 5 to 100 mJ/cm², then post-exposure baked (PEB) on a hot plate at 60 to 150° C. for 1 to 5 minutes, and preferably at 80 to 130° C. for 1 to 3 minutes. Finally, development is carried out using as the developer an aqueous alkali solution, such as a 0.1 to 5% (preferably 2 to 3%) aqueous solution of tetramethylammonium hydroxide (TMAH), this being done by a conventional method such as dipping, puddling, or spraying for a period of 0.1 to 3 minutes, and preferably 0.5 to 2 minutes. These steps result in the formation of the desired pattern on the substrate. Of the various types of high-energy radiation that may be used, the resist composition of the invention is best suited to fine pattern formation with, in particular, deep-UV rays having a wavelength of 248 to 193 nm, an excimer laser, x-rays, or an electron beam. The desired pattern may not be obtainable outside the upper and lower limits of the above range.

The resist composition comprising the polymer as a base resin is sensitive to high-energy radiation, has excellent sensitivity, resolution, and etching resistance, and lends itself to micropatterning with electron beams or deep-UV rays. Especially because of the minimized absorption at the exposure wavelength of an ArF or KrF excimer laser, a finely defined pattern having sidewalls perpendicular to the substrate can easily be formed.

EXAMPLE

Synthesis Examples and Examples are given below by way of illustration and not by way of limitation.

Synthesis Example 1

Ester compounds were synthesized in accordance with the following formulation.

Synthesis Example 1-1

Synthesis of Monomer 1

A flask was charged with 13.6 g of magnesium and 300 ml of tetrahydrofuran, to which 60.3 g of 1,4-dibromobutane was added dropwise at 50° C. After the completion of dropwise addition, the solution was stirred at 60° C. for one hour. To the solution below 40° C., 31.0 g of ethyl tetrahydrofurancarboxylate was added dropwise. The solution was stirred at room temperature for one hour, after which an aqueous solution of ammonium chloride was added for hydrolysis. Ordinary post-treatment yielded 30.2 g of 1-(2-tetrahydrofuranyl)cyclopentanol.

In 80 ml of toluene were dissolved 16.8 g of 1-(2-tetrahydrofuranyl)cyclopentanol, 13.1 g of triethylamine, and 0.5 g of 4-(N,N-dimethylamino)pyridine. Then 10.7 g of acrylic chloride was added to the solution at 50° C., which was stirred at the temperature for one hour. Water, 50 ml, was added to the solution below 30° C., followed by ordinary post-treatment. Vacuum distillation yielded 18.1 g of 1-(2-tetrahydrofuranyl)cyclopentyl acrylate. The two-step yield was 80%.

boiling point: 84-86° C./86 Pa

IR (thin film): ν=2954, 2871, 1720, 1635, 1619, 1450, 1402, 1298, 1207, 1170, 1074, 1049, 983, 811 cm⁻¹

¹H-NMR (300 MHz in CDCl₃): δ=1.49-2.25 (12H, m), 3.70-3.92 (2H, m), 4.57 (1H, t), 5.72 (1H, dd), 6.04 (1H, dd), 6.29 (1H, dd) ppm

Synthesis Example 1-2

Synthesis of Monomer 2

A flask was charged with 240 ml of a solution of 1M methylmagnesium chloride in tetrahydrofuran, to which 15.6 g of methyl 7-oxa-2-norbornanecarboxylate was added dropwise below 40° C. The solution was stirred at room temperature for one hour, after which an aqueous solution of ammonium chloride was added for hydrolysis. Ordinary post-treatment yielded 14.8 g of 2-(7-oxanorbornan-2-yl)-2-propanol.

In 80 ml of toluene were dissolved 12.5 g of 2-(7-oxanorbornan-2-yl)-2-propanol, 12.1 g of triethylamine, and 0.4 g of 4-(N,N-dimethylamino)pyridine. Then 9.1 g of acrylic chloride was added to the solution at 50° C., which was stirred at the temperature for one hour. Water, 50 ml, was added to the solution below 30° C., followed by ordinary post-treatment. Vacuum distillation yielded 13.8 g of 2-(7-oxanorbornan-2-yl)-2-propyl acrylate. The two-step yield was 82%.

boiling point: 86-88° C./40 Pa

IR (thin film): ν=2978, 2950, 2873, 1720, 1635, 1467, 1452, 1402, 1367, 1299, 1232, 1207, 1166, 1136, 1045, 998, 930, 887, 847, 811, 777 cm⁻¹

¹H-NMR of major isomer (300 MHz in CDCl₃): δ=1.41-1.93 {11H, m including 1.53 (3H, s) and 1.61 (3H, s)}, 2.07-2.18 (2H, m), 4.47 (1H, t), 4.58 (1H, t), 5.75 (1H, dd), 6.03 (1H, dd), 6.31 (1H, dd) ppm

Synthesis Example 1-3

Synthesis of Monomer 3

The procedure of Synthesis Example 1-2 was repeated except that methacrylic chloride was used instead of acrylic chloride, obtaining 2-(7-oxanorbornan-2-yl)-2-propyl methacrylate. The two-step yield was 76%.

boiling point: 87-88° C./27 Pa

IR (thin film): ν=2977, 2952, 2910, 2873, 1712, 1637, 1469, 1452, 1400, 1384, 1367, 1326, 1305, 1240, 1207, 1180, 1159, 1133, 1029, 1000, 973, 931, 887, 848, 815, 783, 777 cm⁻¹

¹H-NMR of major isomer (300 MHz in CDCl₃): δ=1.46-1.68{9H, m including 1.52 (3H, s) and 1.62 (3H, s)}, 1.69-1.82 (1H, m), 1.83-1.93 (4H, m), 2.08-2.18 (2H, m), 4.48 (1H, t), 4.58 (1H, t), 5.50 (1H, m), 5.99 (1H, m) ppm

Synthesis Example 1-4

Synthesis of Monomer 4

A flask was charged with 14.6 g of magnesium and 270 ml of tetrahydrofuran, to which 64.8 g of 1,4-dibromobutane was added dropwise at 50° C. After the completion of dropwise addition, the solution was stirred at 60° C. for one hour. To the solution below 40° C., 39.0 g of methyl 7-oxa-2-norbornanecarboxylate was added dropwise. The solution was stirred at room temperature for one hour, after which an aqueous solution of ammonium chloride was added for hydrolysis. Ordinary post-treatment yielded 43.7 g of 1-(7-oxanorbornan-2-yl)cyclopentanol.

In 80 ml of toluene were dissolved 18.2 g of 1-(7-oxanorbornan-2-yl)cyclopentanol, 15.2 g of triethylamine, and 0.5 g of 4-(N,N-dimethylamino)pyridine. Then 12.5 g of acrylic chloride was added to the solution at 50° C., which was stirred at the temperature for one hour. Water, 50 ml, was added to the solution below 30° C., followed by ordinary post-treatment. Vacuum distillation yielded 19.7 g of 1-(7-oxanorbornan-2-yl)cyclopentyl acrylate. The two-step yield was 84%.

boiling point: 95-98° C./29 Pa

IR (thin film): ν=2960, 2873, 1720, 1633, 1619, 1469, 1450, 1402, 1332, 1297, 1280, 1197, 1168, 1120, 1045, 998, 985, 962, 944, 881, 811 cm⁻¹

¹H-NMR of major isomer (600 MHz in CDCl₃): δ=1.31 (1H, dd), 1.41-1.48 (1H, m), 1.52-1.93 (9H, m), 1.99-2.05 (1H, m), 2.22-2.26 (1H, m), 2.35-2.43 (1H, m), 2.75-2.81 (1H, m), 4.39 (1H, t), 4.57 (1H, t), 5.75 (1H, dd), 6.04 (1H, dd), 6.31 (1H, dd) ppm

Synthesis Example 1-5

Synthesis of Monomer 5

The procedure of Synthesis Example 1-4 was repeated except that methacrylic chloride was used instead of acrylic chloride, obtaining 1-(7-oxanorbornan-2-yl)cyclopentyl methacrylate. The two-step yield was 73%.

boiling point: 94-96° C./13 Pa

IR (thin film): ν=2975, 2956, 2873, 1712, 1637, 1469, 1450, 1400, 1376, 1328, 1303, 1270, 1180, 1159, 1002, 987, 939, 883, 848, 815 cm⁻¹

¹H-NMR of major isomer (300 MHz in CDCl₃): δ=1.30 (1H, dd), 1.41-1.50 (1H, m), 1.52-2.07 (13H, m), 2.16-2.18 (1H, m), 2.35-2.47 (1H, m), 2.78-2.89 (1H, m), 4.38 (1H, t), 4.57 (1H, t), 5.49 (1H, m), 5.99 (1H, m) ppm

Synthesis Example 1-6

Synthesis of Monomer 6

Monomer 1, 29.5 g, was dissolved in 30 ml of toluene, to which 11.6 g of cyclopentadiene was added dropwise below 30° C. The solution was stirred at 50° C. for 10 hours. Vacuum distillation yielded 37.1 g of 1-(2-tetrahydrofuranyl)-cyclopentyl 5-norbornene-2-carboxylate. The yield was 96%.

boiling point: 116-118° C./33 Pa

IR (thin film): ν=2971, 2871, 1727, 1448, 1336, 1270, 1232, 1203, 1167, 1108, 1072, 1024, 995, 937, 865, 839, 711 cm⁻¹

¹H-NMR of major isomer (300 MHz in CDCl₃): δ=1.20-2.25 (17H, m), 2.81-2.94 (2H, m), 3.16(1H, s), 3.68-3.89 (2H, m), 4.47 (1H, t), 5.86-5.97 (1H, m), 6.14-6.22 (1H, m) ppm

Synthesis Example 1-7

Synthesis of Monomer 7

The procedure of Synthesis Example 1-6 was repeated except that Monomer 2 was used instead of Monomer 1, obtaining 2-(7-oxanorbornan-2-yl)-2-propyl 5-norbornene-2-carboxylate. The yield was 95%.

boiling point: 120-122° C./13 Pa

IR (thin film): ν=3060, 2973, 2946, 2871, 1727, 1463, 1450, 1382, 1365, 1336, 1301, 1272, 1253, 1230, 1205, 1187, 1164, 1133, 1108, 1027, 998, 973, 931, 917, 887, 838, 815, 709 cm⁻¹

¹H-NMR of major isomer (600 MHz in CDCl₃): δ=1.27 (1H, t), 1.35-1.67 (11H, m), 1.72-1.91 (3H, m), 2.05-2.24 (2H, m), 2.88-2.91 (2H, m), 3.18 (1H, s), 4.46 (1H, t), 4.57-4.61 (1H, m), 5.88-5.95 (1H, m), 6.18-6.21 (1H, m) ppm

Synthesis Example 1-8

Synthesis of Monomer 8

The procedure of Synthesis Example 1-6 was repeated except that Monomer 4 was used instead of Monomer 1, obtaining 1-(7-oxanorbornan-2-yl)cyclopentyl 5-norbornene-2-carboxylate. The yield was 93%.

boiling point: 132-135° C./13 Pa

IR (thin film): ν=3060, 2973, 2871, 1725, 1471, 1448, 1334, 1270, 1230, 1191, 1164, 1132, 1108, 1022, 1000, 941, 883, 838, 815, 709 cm⁻¹

¹H-NMR of major isomer (600 MHz in CDCl₃): δ=1.24-1.33 (4H, m), 1.47-1.69 (6H, m), 1.74-1.92 (5H, m), 2.01-2.19 (2H, m), 2.23-2.33 (1H, m), 2.66-2.71 (1H, m), 2.87-2.91 (2H, m), 3.17 (1H, s), 4.36-4.40 (1H, m), 4.54-4.59 (1H, m), 5.90-5.95 (1H, m), 6.17-6.21 (1H, m) ppm

Synthesis Example 2

Polymers within the scope of the invention were synthesized according to the following formulation.

Synthesis Example 2-1

Synthesis of Polymer 1

To 1500 g of tetrahydrofuran were added 78.5 g of Monomer 1, 70.9 g of hydroxyadamantyl methacrylate, and 77.8 g of 4-oxatricyclo[4.2.1.0^(3,7)]nonan-5-on-2-yl methacrylate. The reaction mixture was heated at 60° C., combined with 6.4 g of 2,2′-azobis(2,4-dimethylvaleronitrile), and then stirred at 60° C. for 15 hours. After cooling to room temperature, the reaction solution was added dropwise to 9 liters of methanol under vigorous stirring. The resulting solids were collected by filtration and vacuum dried at 40° C. for 15 hours. There was obtained 209 g of a polymer in white powder solid form, designated Polymer 1. The yield was 92%. Note that Mw is a weight average molecular weight as measured by gel permeation chromatography (GPC) using polystyrene standards.

Synthesis Examples 2-2 to 2-7

Synthesis of Polymers 2 to 7

Polymers 2 to 7 were synthesized by the same procedure as above or a well-known procedure.

EXAMPLE

Resist compositions were formulated using the inventive polymers as a base resin and examined for line density dependency and resolution.

Examples 1-7 & Comparative Examples 1-2

Resist compositions were prepared by dissolving the inventive polymers (Polymers 1 to 7) or comparative polymers (Polymers 8 to 9 shown below), a photoacid generator, and a basic compound in a solvent in accordance with the formulation shown in Table 1. These compositions were each filtered through a Teflon filter (pore diameter 0.2 μm), thereby giving resist solutions.

These resist solutions were spin-coated onto silicon wafers on which an anti-reflection film (AR-19 by Shipley) of 82 nm thick had been coated and baked at 200° C. for 60 seconds, then baked on a hot plate at 130° C. for 90 seconds to give resist films having a thickness of 0.3 μm. The resist films were exposed using an ArF excimer laser stepper (Nikon Corporation; NA 0.68, σ0.75), then heat treated at 110° C. for 90 seconds, and puddle developed with a solution of 2.38% tetramethylammonium hydroxide in water for 30 seconds, thereby giving line-and-space patterns. The developed wafers were cut, and the cross section was observed under a sectional scanning electron microscope (SEM). The optimum exposure (Eop, mJ/cm2) was defined as the exposure which provided a 1:1 resolution at the top and bottom of a 0.13 μm line-and-space pattern. The resolution of the resist under evaluation was defined as the minimum line width (μm) of the lines and spaces that separated at this exposure. Measured for evaluating line density dependency was the line width of line-and-space 1:10 solitary lines at the same exposure. The line width of group lines minus the line width of solitary lines is the dimensional difference (nm) between sparse and dense patterns. Also the shape of the resist pattern was classified into rectangular, rounded head, T-top, forward taper or reverse taper.

The composition and test results of the resist materials in Examples and Comparative Examples are shown in Table 1. The photoacid generator, basic compound and solvent used are as follows. It is noted that the solvent contained 0.01% by weight of surfactant FC-430 (Sumitomo 3M Co., Ltd.).

TPSNf: triphenylsulfonium nonafluorobutanesulfonate

TMMEA: trismethoxymethoxyethylamine

PGMEA: propylene glycol monomethyl ether acetate TABLE 1 Photoacid Basic Dimensional Resin generator compound Solvent Eop Resolution difference (pbw) (pbw) (pbw) (pbw) (mJ/cm²) (μm) (nm) Shape Example 1-1 Polymer 1 TPSNf TMMEA PGMEA 25 0.11 5 rectangular (80) (1.090) (0.236) (480) 1-2 Polymer 2 TPSNf TMMEA PGMEA 22 0.11 5 rectangular (80) (1.090) (0.236) (480) 1-3 Polymer 3 TPSNf TMMEA PGMEA 19 0.11 6 rectangular (80) (1.090) (0.236) (480) 1-4 Polymer 4 TPSNf TMMEA PGMEA 21 0.11 6 rectangular (80) (1.090) (0.236) (480) 1-5 Polymer 5 TPSNf TMMEA PGMEA 20 0.11 6 rectangular (80) (1.090) (0.236) (480) 1-6 Polymer 6 TPSNf TMMEA PGMEA 28 0.11 6 rectangular (80) (1.090) (0.236) (480) 1-7 Polymer 7 TPSNf TMMEA PGMEA 18 0.11 5 rectangular (80) (1.090) (0.236) (480) Comparative 1-1 Polymer 8 TPSNf TMMEA PGMEA 35 0.13 9 T-top Example (80) (1.090) (0.236) (480) 1-2 Polymer 9 TPSNf TMMEA PGMEA 25 0.13 10 forward (80) (1.090) (0.236) (480) taper

It is seen from Table 1 that using the polymers within the scope of the invention, resist compositions having a high sensitivity, high resolution and minimized line density dependency are formulated.

Japanese Patent Application No. 2002-285161 is incorporated herein by reference.

Although some preferred embodiments have been described, many modifications and variations may be made thereto in light of the above teachings. It is therefore to be understood that the invention may be practiced otherwise than as specifically described without departing from the scope of the appended claims. 

1. An ester compound having the general formula (1):

wherein A¹ is a polymerizable functional group having a carbon-to-carbon double bond, A² is tetrahydrofurandiyl, R¹ and R² bond together to form an aliphatic hydrocarbon ring with the carbon atom to which they are bonded, and R³ is hydrogen or a straight, branched, or cyclic monovalent hydrocarbon group having 1 to 10 carbon atoms which may contain a hetero atom.
 2. A polymer comprising recurring units derived from the ester compound of claim
 1. 3. A polymer comprising recurring units of any one of the general formulae (1b) and (1c):

wherein A² is a divalent group selected from among furandiyl, and tetrahydrofurandiyl, R¹ and R² bond together to form an aliphatic hydrocarbon ring with the carbon atom to which they are bonded, R³ is hydrogen or a straight, branched, or cyclic monovalent hydrocarbon group having 1 to 10 carbon atoms which may contain a hetero atom, and k¹ is 0 or
 1. 4. The polymer of claim 3, further comprising recurring units of any one of the general formulae (M1) to (M13):

wherein R⁰⁰¹ is hydrogen, methyl or CH₂CO₂R⁰⁰³; R⁰⁰² is hydrogen, methyl or CO₂R⁰⁰³; R⁰⁰³ is a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms; R⁰⁰⁴ is hydrogen or a monovalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group; at least one of R⁰⁰⁵ to R⁰⁰⁸ represents a monovalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group while the remaining R's independently represent hydrogen or a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms, or R⁰⁰⁵ to R⁰⁰⁸, taken together, may form a ring, and in that event, at least one of R⁰⁰⁵ to R⁰⁰⁸ is a divalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group, while the remaining R's are independently single bonds or straight, branched or cyclic alkylene groups of 1 to 15 carbon atoms; R⁰⁰⁹ is a monovalent hydrocarbon group of 2 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide; at least one of R⁰¹⁰ to R⁰¹³ is a monovalent hydrocarbon group of 2 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide, while the remaining R's are independently hydrogen or straight, branched or cyclic alkyl groups of 1 to 15 carbon atoms, or R⁰¹⁰ to R⁰¹³, taken together, may form a ring, and in that event, at least one of R⁰¹⁰ to R⁰¹³ is a divalent hydrocarbon group of 1 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide, while the remaining R's are independently single bonds or straight, branched or cyclic alkylene groups of 1 to 15 carbon atoms; R⁰¹⁴ is a polycyclic hydrocarbon group having 7 to 15 carbon atoms or an alkyl group containing a polycyclic hydrocarbon group; R⁰¹⁵ is an acid labile group; X is CH₂ or an oxygen atom or sulfur atom; Y′ is —O— or —(NR^(f))—; R^(f) is hydrogen atom or a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms; and letter k is 0 or
 1. 5. A resist composition comprising the polymer of claim
 3. 6. A process for forming a resist pattern comprising the steps of: applying the resist composition of claim 5 onto a substrate to form a coating, heat treating the coating and then exposing it to high-energy radiation or electron beams through a photomask, and optionally heat treating the exposed coating and developing it with a developer.
 7. An ester compound having the general formula:

wherein A² is tetrahydrofurandiyl, R¹ and R² bond together to form an aliphatic hydrocarbon ring with the carbon atom to which they are bonded, R³ is hydrogen or a straight, branched or cyclic monovalent hydrocarbon group having 1 to 10 carbon atoms which may contain a hetero atom, and R⁴ is hydrogen or methyl.
 8. A polymer comprising recurring units of the general formula (1a):

wherein A² is a divalent group selected from among furandiyl and tetrahydrofurandiyl, R¹ and R² bond together to form an aliphatic hydrocarbon ring with the carbon atom to which they are bonded, R³ is hydrogen or a straight, branched or cyclic monovalent hydrocarbon group having 1 to 10 carbon atoms which may contain a hetero atom, and R⁴ is hydrogen or methyl.
 9. The polymer of claim 8, further comprising recurring units of any one of the general formulae (M1) to (M13):

wherein R⁰⁰¹ is hydrogen, methyl or CH₂CO₂R⁰⁰³; R⁰⁰² is hydrogen, methyl or CO₂R⁰⁰³; R⁰⁰³ is a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms; R⁰⁰⁴ is hydrogen or a monovalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group; at least one of R⁰⁰⁵ to R⁰⁰⁸ represents a monovalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group while the remaining R's independently represent hydrogen or a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms, or R⁰⁰⁵ to R⁰⁰⁸, taken together, may form a ring, and in that event, at least one of R⁰⁰⁵ to R⁰⁰⁸ is a divalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group, while the remaining R's are independently single bonds or straight, branched or cyclic alkylene groups of 1 to 15 carbon atoms; R⁰⁰⁹ is a monovalent hydrocarbon group of 2 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide; at least one of R⁰¹⁰ to R⁰¹³ is a monovalent hydrocarbon group of 2 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide, while the remaining R's are independently hydrogen or straight, branched or cyclic alkyl groups of 1 to 15 carbon atoms, or R⁰¹⁰ to R⁰¹³, taken together, may form a ring, and in that event, at least one of R⁰¹⁰ to R⁰¹³ is a divalent hydrocarbon group of 1 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide, while the remaining R's are independently single bonds or straight, branched or cyclic alkylene groups of 1 to 15 carbon atoms; R⁰¹⁴ is a polycyclic hydrocarbon group having 7 to 15 carbon atoms or an alkyl group containing a polycyclic hydrocarbon group; R⁰¹⁵ is an acid labile group; X is CH₂ or an oxygen atom or sulfur atom; Y′ is —O— or —(NR^(f))—; R^(f) is hydrogen atom or a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms; and letter k is 0 or
 1. 10. A resist composition comprising the polymer of claim
 8. 11. A process for forming a resist pattern comprising the steps of: applying the resist composition of claim 10 onto a substrate to form a coating, heat treating the coating and then exposing it to high-energy radiation or electron beams through a photomask, and optionally heat treating the exposed coating and developing it with a developer.
 12. An ester compound selected from the group consisting of compounds having any one of the following formulae:


13. A polymer comprising recurring units derived from the ester compound of claim
 12. 14. The polymer of claim 13, further comprising recurring units of any one of the general formulae (M1) to (M13):

wherein R⁰⁰¹ is hydrogen, methyl or CH₂CO₂R⁰⁰³; R⁰⁰² is hydrogen, methyl or CO₂R⁰⁰³; R⁰⁰³ is a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms; R⁰⁰⁴ is hydrogen or a monovalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group; at least one of R⁰⁰⁵ to R⁰⁰⁸ represents a monovalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group while the remaining R's independently represent hydrogen or a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms, or R⁰⁰⁵ to R⁰⁰⁸, taken together, may form a ring, and in that event, at least one of R⁰⁰⁵ to R⁰⁰⁸ is a divalent hydrocarbon group of 1 to 15 carbon atoms having a carboxyl or hydroxyl group, while the remaining R's are independently single bonds or straight, branched or cyclic alkylene groups of 1 to 15 carbon atoms; R⁰⁰⁹ is a monovalent hydrocarbon group of 2 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide; at least one of R⁰¹⁰ to R⁰¹³ is a monovalent hydrocarbon group of 2 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide, while the remaining R's are independently hydrogen or straight, branched or cyclic alkyl groups of 1 to 15 carbon atoms, or R⁰¹⁰ to R⁰¹³, taken together, may form a ring, and in that event, at least one of R⁰¹⁰ to R⁰¹³ is a divalent hydrocarbon group of 1 to 15 carbon atoms containing at least one partial structure selected from among ether, aldehyde, ketone, ester, carbonate, acid anhydride, amide and imide, while the remaining R's are independently single bonds or straight, branched or cyclic alkylene groups of 1 to 15 carbon atoms; R⁰¹⁴ is a polycyclic hydrocarbon group having 7 to 15 carbon atoms or an alkyl group containing a polycyclic hydrocarbon group; R⁰¹⁵ is an acid labile group; X is CH₂ or an oxygen atom or sulfur atom; Y′ is —O— or —(NR^(f))—; R^(f) is hydrogen atom or a straight, branched or cyclic alkyl group of 1 to 15 carbon atoms; and letter k is 0 or
 1. 15. A resist composition comprising the polymer of claim
 14. 16. A process for forming a resist pattern comprising the steps of: applying the resist composition of claim 15 onto a substrate to form a coating, heat treating the coating and then exposing it to high-energy radiation or electron beams through a photomask, and optionally heat treating the exposed coating and developing it with a developer.
 17. The ester compound of claim 1, wherein A¹ is selected from the group consisting of vinyl, allyl, 1-propenyl, isopropenyl, and tetracyclo[4.4.0.1^(2,5).1^(7,10) ]dodecyl.
 18. A polymer comprising recurring units derived from the ester compound of claim
 17. 19. A resist composition comprising the polymer of claim
 18. 